BUS CODE

&
BUS SAFETY TECHNOLOGIES

BUS WORLD ACADEMY 2015

Mumbai
29th April 2015

A. A. Badusha
Deputy Director & Head
Vehicle Evaluation Laboratory
ARAI Introduction

Impact of Road Safety on Mass Transportation

Bus Code Status and Constructional Safety Features

Bus Body Builders Facility Accreditation

Future Active Safety Technologies for Buses

Future Passive Safety Technologies for Buses

Bus Development Capabilities at ARAI

Establishment : 1966
Location : Pune, INDIA (150 km from Mumbai)
Manpower : 600+
Facilities : 12 Laboratories Powertrain, Emissions, Safety &
Homologation, Passive Safety, Vehicle Evaluation, Materials,
Automotive Electronics, NVH, CAE, Structural Dynamics,
Calibration, Post Graduate Academy, Forging Industry Division
Our Offices : China, Korea and Chennai
Investments : USD $ 60 Million
Accreditations : ISO 9001, 14001, OHSAS 18001 & NABL ( ISO/IEC 17025)
 Engaged in sponsored R&D work and Development
Testing.
Ministry approved test agency to carry out certification
testing.
ARAI is actively engaged in
Preparation & Harmonization of standards.
Secretariat for AISC , CMVR-TSC & WP29.
Deliberation of policy matters affecting Auto R&D.
Creation of facilities and building up competence
by undertaking forward looking research &
technology demonstration projects.
Education & Training
Consulting Services
 2015-16 (P)
31.9
2010-11 17.9

2009-10 14.1

11.3
2008-09
10.9
2007-08
11.1
2006-07 9.7
8.5
2005-06

2004-05

0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0

2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2015-16 (P)
PVs 1.2 1.3 1.6 1.8 1.9 2.4 3.0 2.6
CVs 0.3 0.4 0.5 0.5 0.4 0.6 0.8 0.6
3Ws 0.4 0.4 0.5 0.5 0.5 0.6 0.8 0.9
2Ws 6.6 7.6 8.5 8.1 8.4 10.5 13.3 27.8
Source: SIAM and IBEF Presentation on Automotives, Projections as per AMP 2006-
Nov10 16 All Vehicles: 31.9
million
Rising Trend of Indian Road Fatality in the decade (2001- 2010)
Prime reason of Traffic Congestion !!!
Source: Estimation of Automobile emissions and control strategies
K.S.Nesamani, University of California, 2009
Road safety Safer roads Safer Safer road Post-crash
management and mobility vehicles users response
Bus production in India and the World

(Figures in Thousands)

2007 2008 2009 2010

Asia-Oceania 424 503 213 260
Europe 90 97 56 57
America 68 70 58 68
World production 587 703 333 392

China 344 447 129 161

India 44 44 42 54

Sources : OICA
 Indian Scenario
Current production of buses in india is 54,000.

MoUD estimate of urban bus requirement by 11th Five Year Plan

is 1,50,000 buses.

Majority of buses built on drive-away truck chassis by large

number of bus body builders (>6000) in unorganized sector.

Only about 20 body builders and OEMs are in organized sector.

Capacity of the bus body building industry is very limited.

Most of the designs developed by experience not much of

engineering only recently some designs of semi-low, low floor
of imported origin evolving.
 Data from MoRTH website

However, Bus Accidents although fewer in numbers, attract large

attention because they can be catastrophic !
 More use
of
Personal
Mobility

More Congestion
Roads

More use
of More
Personal Roads
Mobility
Road Segregated roads for Buses
Infrastructure
Road furniture Road Restraint systems

Traffic Traffic controls

Management Congestion avoidance policies , techniques
Intelligent Transport system (ITS)
Electronic Stability Control, Antilock Braking Systems, Retarders etc.,
Vehicle
Technology Speed control techniques
Super structure design for rollover safety

Enforcement Bus Code Implementation (AIS 052)

of Safety Laws
Occupant Safety
Lighting and Signaling devices
 Rapid build-up in infrastructure has left some voids
which is causing increasing number of accidents on
roads causing large number of accidental deaths
due to ;
- Vehicles overrunning speed limits
- Mixed traffic conditions
- Lack of road restraint infrastructure
- Lack of Emergency Services
Lack of Driver education
Bus Structure Design to Passive safety
requirements
Law enforcement
Lack of Public awareness Education
Lack of Transportation Planning
 To ensure minimum levels of safety and comfort across the Bus
industry in India.
Because of globalization, international players have entered Indian
Bus Market. It has created fierce competition.
Customer is becoming more demanding and looking for better safety
and comfort. It necessitates High-End Engineering Capability for Bus
design.
Need to Optimize design for contradictory parameters viz. Safety,
Reliability, Weight, Manufacturability and Cost.
Built in Quality - in manufacturing calls for detailed engineering
efforts, modern manufacturing facilities and good quality control
system.
Body Builders need to transform to become a complete engineering
industry with good design capability besides manufacturing and
quality.
 The Bus Body Code is the result of involved stakeholders like ARAI,
CIRT, ASRTU, Transport Corporations, Transport Officials, Vehicle
manufacturers, and other test agencies.
The Code was finalized in 2001 and submitted to the Ministry of
Shipping, Road Transport & Highways.
The Code has been circulated to all the State Transport Undertakings
(STUs) by ASRTU.
The Code has been approved by the Transport Development Council.
The Code has been notified by the Ministry under the CMVR, vide
GSR 589 (E) dated 16th September 2005.
Bus Body Code (AIS-052) underwent revision (i.e. Revision-1) in
October 2007 and was amended to keep pace with changes.
The Bus Code has become effective from 1st of April 2015.
Type Approval of a Bus basically involves;
Vehicular System Level Tests
Component Level Tests
Bus Prototype Testing, Verification and Approvals
Conformity of Production (CoP) at a later stage
 Seat Belt
Horn Anchorages
Seat Belts
Rear View
Mirror
Seats

Window
glasses
CNG-LPG
Components
Window
frames

Safety Glass

Flammability
test for
material
Wheel rim

Lighting &
Signaling
Hinges &
devices
Latches
Plastic Fuel
Tank Metallic Fuel
Tank
 Service Doors - Number and Dimensions.
Windows & Window frames.
Guard Rails.
Emergency Exits Number and Dimensions.
Steps Number and Dimensions.
Floor Height.
Hand Rails and Hand Holds.
Gangway Requirements.
Seat Layout & Seat Dimensions for Passengers.
Driver and Co-Driver Seat Dimensions & Requirements.
 Contd..
Laminated Windscreen Safety Glass (IS:2553)
Seat Belts (IS : 15140)
Strength of Seats (AIS : 023).
Door Locks & Hinges (IS : 14225).
Window Retention & Release (IS : 13944).
Passenger Hand Holds (AIS : 046).
Fuel tanks ( Metallic - IS:14681 / Plastic - AIS:033)
Lighting and Signaling Devices and their Installation (AIS:012)
Horns & Installation of Horns (IS:1884 & AIS:014)
Rear View Mirrors and their Installation ( AIS:001 & AIS:002)
Windscreen Wiping System ( AIS:011)
Flammability test for vehicle interior components (IS : 15061).
 Strength of Super Structure / Roll over (AIS : 031).
Stability test for 28 degrees tilt.
Provisions for Fire Extinguishers
Modular Window Frames ( AIS:065)
Hat racks.
Bumper Fitment.
Drivers Workplace Requirements.
Standee Passenger Area Calculation Procedure.
Provisions for Differently Enabled Persons.
Body Structure and Material.
Operation of Automatic Service Doors.
Provisions for School Bus.
Ingress of Water - Optional Requirement (IS : 11865).
Ingress of Dust - Optional Requirement (IS : 11739).
 Roll-over test on
complete vehicle

Roll-over test on
body sections

Verification by
simulation or
calculation
Requirement :

The vehicle shall not

overturn, when the
surface on which the
vehicle stands is fitted to
both sides in turn at an
angle of 28 degrees from
the horizontal.

Loading of the vehicle

should be uniform @
75kg / seat + Standees
weight + roof luggage as
applicable.
 Ingress of rain water (Optional)
All doors, windows and latches
shall not allow ingress of rain
water when in the closed
position in accordance with
IS:11865.

Ingress of dust (Optional)

All doors, windows and latches
shall not allow ingress of dust
when in the closed position and
when tested in accordance with
IS : 11739
Materials used for the following shall comply with the burning
rate requirements when tested as per IS:15061.

Upholstery of any seat and its accessories.

Interior roof lining.
Interior lining of the side and rear walls.
Materials with thermal and / or acoustic functions.
Interior lining of luggage racks, heating and ventilation pipe.
Luminaries.
Curtains, blinds or other hanging material.
 Speed
Driver Climb Limiting Retro
facility Devices Reflective
Passenger Tape
Hand holds

Standee
Field Of Passenger
Vision Area

Wiping Dimensional
System Checks

Accelerator Mirror
Control test Installation

Drivers
Work Place
Interior Fittings
Lighting RUPD & Horn
Installation SUPD Installation
 Priority Signs

Priority Seats

Handrails / Stanchions to be provided for the

disabled to grasp and assist while boarding.

Controls to be provided near the priority seats

for requesting stops.

Public address system or digitized messages

permitting the driver to inform passengers
about destinations and stops.
 Accreditation of Bus Body Builders facility was initiated by the
Government vide S.O. 2356 E dated 03 Oct, 2012, and is effective
from 1st of April 2013.

Accreditation is applicable to :
Companies, Individuals engaged in bus manufacturing.
Bus body building of M2 and M3 type of vehicles (as per
AIS:053) type of vehicles having seating capacity 13 or more
passengers.
All types of buses which are covered under Bus Code.
Addresses Land area, Process Definition & Quality control,
Quality Checks, Manpower competency, Shower test facility.
Two categories A and B based on the activities undertaken.
Category A For those Who build the full bus
Category B For those who build buses on bought out
Chassis
 18.70% 18.60%

5.20%

5.80% 13.40%

6.70%
5.40% 13.90%
12.30%

Over Speed Right of Way Turns

Driving Too Close Influence of Alcohol Misuse of Road
Failure during passing Pedestrians Others
 Remove blind spots the vital need to
improve visibility
Device for indirect vision other than
(conventional) mirror can be used for
Class V + Class VI areas
Body Builders fitting twin camera
systems (mainly side and rear view)
with split screen monitor
 Anti-Lock Braking Systems (ABS) are used to prevent
locking of a vehicles wheels as a result of excessive
actuation of service braking system, especially on
slippery roads

ABS is getting mandated in India for

all M3 and N3 categories of vehicles.
 ESP reduces the risk of the driver losing control over his vehicle in
critical situations, for example in sharp curves or on slippery
surfaces.

Different sensors in the system monitor the behavior of the coach

and interacts with individual wheel braking and even reduction of
engine power, if necessary.

ESP is mandatory in Europe for

Buses with more than eight seats
from 2013 (New Models) & 2015
(New Registration)
 Avoids traffic accidents due to under-inflated tires
by early recognition of the malfunction of tires.

Reduces rolling resistance thus increasing overall

fuel efficiency.

TPMS is mandatory in USA from

2012 for buses
Voluntary requirement in Europe
 The majority of bus fires start in the engine
compartment, usually out of sight of the
bus driver.

Once a fire has started it is important to

detect, control and ultimately extinguish
the fire as early as possible to avoid
injuries, loss of lives, costs related to
property damages

An efficient fire detection and suppression

system can greatly enhances the time
available for safe escape in the event of a
fire.
 Improvement in material used for
the construction of inside of coach
bodywork
Detection Systems: Fire detection
Systems for engine compartment
smoke & heat detection , system for
coach interior
Cable tests, repel tests for insulation
material, burning behavior of
materials

Experimental Mock-up for Detection &

Suppression System in Engine
 At source installation of
detection systems, (fire &
smoke),
Fire suppression systems in the
engine compartment as well as
in luggage & passenger area
Greater use of flame resistant
materials in coach & bodywork
Periodic vehicle inspections
Correct maintenance of all the
mechanical parts of the coaches
Pre/post trip inspection (similar
to aircraft industry) Passenger Compartment Fire
Propagation modeling
 SP Technical Research Institute of Sweden (SP) launched a
project in 2005 with the objective to create a safer
environment for passengers and bus drivers worldwide.

The result is the new certification system: P-mark SPCR 183

Type Test & Factory Audit for QA of the product

In addition all system components included in the full

suppression system such as nozzles, pressure cylinders,
piping, detectors, electronic components, control panels,
are tested for harsh environments, EMC, change in
temperature, corrosion, vibration, humidity extremes etc.
 Use 3 point seat belt and correct restraining of
children.

Develop Seat regulations (R14, R80)

Specify deceleration pulse for M2 vehicles

Protect driver / co-driver in frontal impact

Improve compatibility between buses and

other vehicles

Design frontal structures with FUPD Front

Under run Protective Devices
 Outside - Emergency button.

Inside Clear marking emergency

of exits.

Outside / Inside : Central locking /

unlocking of all doors &
emergency windows with one all
round vehicle operating device.

Better gangway design to allow

free movement of passengers.

Provide emergency lights over

emergency exits.
Simulators for Motor EDR / Tachograph for Trip Mandatory Resting
coach Driver Training Monitoring Times
Driver interaction system:
Driver Interaction Support works as a personal
secretary
Prioritises and presents information from the
vehicles different.
The aim is to reduce the workload for the driver in
demanding driving conditions
Driver alert system:
The driver head movement , eye movements and
blinking are monitored to prevent accidents due to
drivers falling asleep at the wheel or being
distracted
Driver visibility:
Cameras above the exits and rear of the bus are
an excellent complement to the rear view
`mirrors.
Driver steering controls :
Controls on the steering wheel aids the driver to
access the necessary and frequent controls
without of being deviated from the road
Lane keeping system:
Lane keeping system calculates the position of
the coach in the road and warns the driver if he is
steering off course
Ignition interlock device or breath alcohol ignition
interlock device (IID and BAIID):
It is a mechanism, like a breathalyzer, installed on
a motor vehicle's dashboard.
The driver first must exhale into the device
Alcohol concentration analyzed result is greater
than the programmed blood alcohol
concentration the device prevents the engine
from being started.
Typical Motor coach in Europe
& USA showing advanced
technical safety features
 Competition
Reduced Lead Times
Reduced Cost
Consumer Improvised Quality Government
Demands Regulations
Looks & Ergonomics New, Improvised &
Price Performance Stringent Regulations

MANUFACTURER
 Body Design for assured safety and optimized body strength.
Reduced fuel consumption achieved in terms of lesser unladen
weight and lower aero-dynamic drag.
Assured passenger comfort in terms of dimensional and seating
requirements.
Design for Noise Vibration and Harshness (NVH).
Design for optimum HVAC.
Internationally Competitive Design for specific applications.
 ARAI can assist Bus industry in
Certification of components, assemblies & complete
vehicle at shortest time and reasonable cost.
Design of Bus Chassis and Superstructure

Virtual validation using computer simulation

Proving of prototype using physical testing

 Bus Body Code - Compliance Evaluation and Certification.
Component testing facilities for all safety Critical Components.
Rollover facility for buses Physical and CAE methods
Tilting Platform, deformable templates and other instrumentations
for rollover of complete bus as per AIS 031 / ECE R66.
High Speed Camera up to 100000 fps, 8 Nos. and image analysis
software.
Crash / Sled test facilities for safety/ occupant protection.
Complete NVH facilities both in lab and in free-field condition.
Ride comfort measurement facilities.
100 channels of data acquisition on running vehicles for accelerated
endurance.
Material testing facilities.
 Joint Strength

Model Building
CG Calculations

Experimental Rollover
Validation Evaluation
 Vibration Analysis

Strength Evaluation
Durability Analysis

Stability Test Rollover Evaluation

 Structural Acoustic
NVH Performance
Simulation

Ride Comfort BUS HVAC Simulation

Simulation
 Developed Bolted and Welded AL
superstructure design meeting
requirements of Bus body code
AIS:052
Developed Steel equivalent AL
section with weight saving of 36%
Developed joint strength
database of Steel and Aluminium
superstructure joints
Developed FEA simulation
methodology for characterizing
AL welded joints, through
simulation and test correlation
Developed Light weight AL Seat
with 35% weight saving compared
to existing bus seat

Target Weight Saving = 1200kg

 Life Cycle requirements
Design for durability Minimum life expectations
UBS II specifications refer for 12 years or 10,00,000 km driving cycle

Performance requirements
Engine operational requirements for high altitude operation and
improved gradeability
Duty cycle running data can be referred for selection of buses
Improved grade ability of 10.2 deg.
AC performance test
Intelligent Transport System

Comfort requirements
In cab noise level at 81 dB(A) from April 2015
AC performance test
 Can carry more number of
passengers reducing the traffic
and saving fuel
Can be plied both in urban and
intercity applications
Can be used for Office
executives

Popular transport in many

countries like USA, UK,
Germany, Japan etc.
Enhances vehicle and
customer safety and comfort
Passenger Information system (PIS):
Route programming
Capability to display and perform voice
announcements of stops with GPS and using
manual intervention in case of GPS failure
Two way communication with Central Control
Centre
Security Camera network system (SCN):
Capability to record through high resolution
cameras inside and outside the bus at
preselected resolution and FPS in the event of
activation of micro emergency pedal.
Capability to transfer the recordings through
WLAN, SD card, USB.
On-board pole mounted ticketing machines :
SCU should be able to provide route , GPS
information in XML format over TCP socket to
ticketing machine
Vehicle health monitoring and diagnostics (VHMD)
Vehicle safety, performance, engine and
transmission parameters are collected by
SCU and create log files & real time warnings
to communicate to Control Centre at the end
of the day via WLAN
Automatic Vehicle Location system (AVL)
SCU will transmit raw GPS data, of the vehicle
locations, in NMEA protocol, via
GPRS/3G(GSM), for further processing and use
, including that for signs on bus stops, BRTS
and bus terminals
Intelligent Transit Management System
Operational Enhanced Capital Higher
Efficiency Service Improvements Productivity
Standards
 High-quality BRT systems, such as
Trans Milenio in Bogota or Macrobus
in Guadalajara, can reduce both
crashes and fatalities on the corridors
by 50 to 60%, due to infrastructure
improvements and reductions in
vehicle travel.

Ahmedabads Bus Rapid Transit (BRT)

system was opened in 2009 and
correctly covers 61 km of network
carrying 1,40,000 passengers Word of caution :
everyday with a projection of
However, if BRTs are not
properly designed safety
carrying 4,00,000 passengers improvements are
everyday. 50% reduction in traffic smaller or non-existent.
fatalities was observed in the BRT
corridor after its launch.
 Electric Buses and Hybrid Electric Buses

BRTs implemented in cities

IT Enabled Infrastructure

Domination of Low Floor buses

Integrated Transport planning considering various

facets of Transportation means including Metro, Rail
Network, Mono-Rails, BRTs, Pedestrian Walkways.
 Developed country is not where poor
have cars. Its where rich use public
transport.
- Enrique Penalosa, former Mayor of Bogot,
Colombia

Safety is, and must always be, the basic

principle for all engineering design.
- Basic principle set by Volvos founders Assar Gabrielsson and Gustaf Larsson
A. A. Badusha
Deputy Director
The Automotive Research
Association of India
Survey No. 102, Vetal Hill, Off Paud
Road,
Kothrud, Pune 411 038
Tel. +91 20 3023 1370
Fax. +91 20 25434190
E-mail. badusha.vel@araiindia.com