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
Manpower

: Pune, INDIA (150 km from Mumbai)

: 600+

Facilities

Our Offices
Investments

: 12 Laboratories Powertrain, Emissions, Safety &

Homologation, Passive Safety, Vehicle Evaluation, Materials,
Automotive Electronics, NVH, CAE, Structural Dynamics,
Calibration, Post Graduate Academy, Forging Industry Division
: China, Korea and Chennai
: 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
14.1

2009-10
11.3

2008-09

10.9
2007-08

11.1
9.7

2006-07

8.5

2005-06

2004-05
0.0

PVs
CVs
3Ws
2Ws

5.0

10.0

2004-05
1.2

2005-06
1.3

2006-07
1.6

2007-08
1.8

2008-09
1.9

2009-10
2.4

2010-11
3.0

0.3
0.4
6.6

0.4
0.4
7.6

0.5
0.5
8.5

0.5
0.5
8.1

0.4
0.5
8.4

0.6
0.6
10.5

0.8
0.8
13.3

Source: SIAM and IBEF Presentation on Automotives,

Nov10

15.0

20.0

25.0

30.0

35.0
2015-16 (P)
2.6

Projections as per AMP 200616 All Vehicles: 31.9

million

0.6
0.9
27.8

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
management

Safer roads
and mobility

Safer
vehicles

Safer road
users

Post-crash
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

Congestion

More
Roads

More use
of
Personal
Mobility

More
Roads

Road
Infrastructure

Segregated roads for Buses

Road furniture Road Restraint systems

Traffic
Management

Traffic controls
Congestion avoidance policies , techniques
Intelligent Transport system (ITS)

Vehicle
Technology

Electronic Stability Control, Antilock Braking Systems, Retarders etc.,

Speed control techniques

Super structure design for rollover safety

Enforcement
of Safety Laws

Bus Code Implementation (AIS 052)

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
requirements

Law enforcement

Lack of Public awareness Education

Lack of Transportation Planning

Design

to

Passive

safety

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

Horn

Seat Belt
Anchorages

Seat Belts

Rear View
Mirror

Seats
Window
glasses
CNG-LPG
Components
Window
frames
Safety Glass

Flammability
test for
material
Wheel rim
Lighting &
Signaling
devices

Hinges &
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
simulation
calculation

by
or

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.

Driver Climb
facility

Speed
Limiting
Devices

Passenger
Hand holds

Retro
Reflective
Tape

Standee
Passenger
Area

Field Of
Vision

Dimensional
Checks

Wiping
System

Mirror
Installation

Accelerator
Control test

Drivers
Work Place
Interior Fittings
Lighting
Installation

RUPD &
SUPD

Horn
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

18.60%

18.70%
5.20%

13.40%

5.80%

6.70%
5.40%

12.30%

Over Speed

Right of Way

Driving Too Close

Influence of Alcohol

Failure during passing

Pedestrians

13.90%

Turns
Misuse of Road
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
, system for
smoke & heat detection
coach interior
Cable tests, repel tests for insulation
material, burning behavior of
materials

Experimental Mock-up for Detection &

Suppression System in Engine

 At

source

detection
smoke),

installation

systems,

(fire

of

&

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

coach Driver Training

EDR / Tachograph for Trip

Monitoring

Mandatory Resting
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
Consumer
Demands

Reduced Lead Times

Reduced Cost
Improvised Quality

Looks & Ergonomics

Price Performance

Government
Regulations
New, Improvised &
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
Validation

Rollover
Evaluation

Vibration Analysis

Strength Evaluation

Stability Test

Durability Analysis

Rollover Evaluation

Structural

Ride Comfort
Simulation

Acoustic
NVH Performance
Simulation

BUS HVAC 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
Efficiency

Enhanced
Service
Standards

Capital
Improvements

Higher
Productivity

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
everyday with a projection of
carrying
4,00,000
passengers
everyday. 50% reduction in traffic
fatalities was observed in the BRT
corridor after its launch.

Word of caution :
However, if BRTs are not
properly designed safety
improvements are
smaller or non-existent.

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