R66 BUS SUPERSTRUCTURE CONCEPT DESIGN DEVELOPMENT LAW SOO HAR

Transcription

1 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 Date : : MR. RAZALI BIN MOHD TIHTH :

2 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

3 i DECLARATION I hereby, declare this thesis is result of my own research except as cited in the references Signature Author Name Date :. : Law Soo Har :.

4 ii DEDICATION To My Beloved Family My Parent Yin Teng

5 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.

6 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.

7 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.

8 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 Background Objectives Scope of Works Problem Statement 5 CHPTER 2 LITERATURE REVIEW The Literatures on Any Things That 8 Related To Bus History of Bus Designs of Bus Type of Bus Single-deckers 10

9 vii CHPTER TITLE PAGE Double-deckers Articulated Buses Low-floor Buses Bi-articulated Open top Coaches Trolley Buses The Use of Bus Public Transport Schools Private Charter Promotion Not for Profit Specialist Users Tourism Bus Manufacturing 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 List of ECE Regulations General Lighting Headlamps Instrumentation / Controls Safety Environmental / 26 Performance The Regulations Used On Bus 27 Structure

10 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 Full-scale vehicle rollover test Bay Section Rollover Test Bay Section Pendulum Impact 34 Test Component Testing The Available Method of Simulation 36 That Related To the R66 Regulations Numerical Test Method Numerical Simulation 37 Model for Vehicle Structure Numerical Simulation 39 Model for Occupant Behavior 2.8 The Fundamental of Computer-aided 40 Engineering CAE Fields and Phase CAE in Automotive Industries CAE Software Finite Element Method (FEM) Impact Analysis of a Falling Object 46 CHAPTER 3 METHODOLOGY Method Used To Test the Bus 49 Structure to Achieve R66 Bus Superstructure

11 ix CHAPTER TITLE PAGE The Reason of Method Use and 51 Software Chosen ADAMS-View Theoretical Impact 51 Impact Calculation Method Static Structural 52 Simulation Method 3.2 Process Flow of Bus Structure 53 Analysis and Simulation 3.3 Residual Space in Bus Model Material Properties of Bus Structure Bus Structure Deformation and Energy 57 Absorb Calculation Solution by Using Theoretical Impact Analysis Method 3.6 Scenarios Investigate 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 Identification of Bus Structure 65 Dimension, Material and Mass Properties 4.2 Dynamic and Kinematic analysis of 67 Rollover Bus Simulated by ADAMS-View ADAMS-View Analysis Setup 67

12 x CHAPTER TITLE PAGE ADAMS-View Analysis Results Rollover Simulation with 68 Bus Structure Only Rollover Simulation with 70 Bus Structure and Passengers Weight Rollover Simulation with 72 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 Rollover Simulation with Bus 74 Structure Only Rollover Simulation with Bus 76 Structure and Passengers Weight Rollover Simulation with Bus 78 Structure, Passengers Weight and Luggage Weight 4.4 The Simulation of Bus Superstructure 80 by MSC. Patran and MSC. Nastran MSC. Patran and MSC. Nastran 80 Analysis Setup The Results of Bus Superstructure 81 Simulation by MSC. Patran and MSC. Nastran Rollover Simulation with 81 Bus Structure Only Rollover Simulation with 83 Bus Structure and

13 xi CHAPTER TITLE PAGE Passengers Weight Rollover Simulation with 84 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 The Overview Design of Bus Structure The Design of Rollover Bar 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 Recommendations 99 REFERENCES 101 APPENDIX APPENDIX APPENDIX APPENDIX 4 112

14 xii LIST OF TABLES NO. TITLE PAGE 1.1 Injury distribution in coach accidents, Spain (Source: Martinez, (2003)) The details of material properties for carbon 57 steel (ASTM A500) (Source: Wikipedia (2010)) The important physical properties of the bus 66 structure The value of impact force in difference 81 investigation scenarios The summary of overall results The comparison of summary results with results 90 from TEMSA 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)) The mass properties of carbon steel square 97 hollow section with standard material ASTM A500 Grade A (Source: Markas Hardware Corporation)

15 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, (Source: National Institute of Aviation Research, (2005)) Double-decker of Kowloon Motor Bus, Hong 10 Kong. (Source: Wikipedia, (2008)) Volvo B10M articulated bus in Adelaide, South 11 Australia. (Source: Wikipedia, (2008)) Coaches parked at Chicken Itza, Mexico. 13 (Source: Wikipedia, (2008)) A local transit bus in Canberra, Australia. 14 (Source: Wikipedia, (2008)) All-over advert bus for Landsbanki in Iceland. 16 (Source: Wikipedia, (2008)) A New York police bus converted for use as a 17 command post. (Source: Wikipedia, 2008)) Chassis bus and space frame bus, deformation 20 comparison. (Source: Technet-alliance, (1990)) City bus sidewall assembly. 20 (Source: Technet-alliance, (1990)) An AEC Routemster, a pioneering 1950s bus 21 design. (Source: Leyland Leopard, (2008)) A 1986 van derived Ford Transit minibus 22

16 xiv bodied by Carlyle. (Source: Leyland Leopard, (2008)) A Volvo B10M chassis, bodied worldwide as a 23 single-decker bus, articulated bus, double-decker bus and coach. (Source: Leyland Leopard, (2008)) ECE R66 bus superstructure 28 (Source: Daimler, (2004)) The optimized seat structures and obligatory 28 integration of seatbelts. (Source: Daimler, (2004)) Definition of residual space. 30 (Source: ECE Regulation No. 66, (2006)) Residual space. (Source: Elitok, (2006)) Specification of the rollover test. 31 (Source: ECE Regulation No. 66, (2006)) The stages of rollover 32 (Source: Hashemi, (2005)) Bay section rollover test 33 (Source: Hashemi, (2005)) Pendulum impact on bay section 34 (Source: Hashemi, (2005)) Quasi-static component testing 35 (Source: Hashemi, (2005)) Dynamic component testing 35 (Source: Hashemi, (2005)) Typical quasi-static test set-ups 35 (Source: Hashemi, (2005)) Quasi-static data processing 36 (Source: Hashemi, (2005)) Pillar-structural behavior (Source: Anon) Rollover model (Source: Anon) Bay section rollover model (Source: Anon) Rollover simulation (Source: Anon) Rollover simulation (bay section) 40

17 xv (Source: Anon) Typical Finite Element Method process flow The diagram of impact analysis of a falling 46 Object (Source: LivePhysics (2010)) Schematic flow of method software used The flow chart of bus structure analysis and 55 simulation process The geometry of tilting table 60 (Source: ECE Regulation No. 66, (2006)) ECE-R66 test setup in the ADAMS-View 61 (Source: Deshmukh, (2006)) Rollover simulation in ADAMS View. 62 (Source: Deshmukh, (2006)) The overall dimension of bus model (side view) The overall dimension of bus model (front view) ADAMS-View analysis setup The bus structure just before impact on the 68 ground The analysis setup of bus structure in the pre- 80 process of simulation by MSC. Patran The result of translational displacement and 82 deformation of bus structure (front view) The result of translational displacement and 82 deformation of bus structure (isometric view) The result of translational displacement and 83 deformation of bus structure with passengers weight (front view) The result of translational displacement and 84 deformation of bus structure with passengers weight (isometric view) The result of translational displacement and 85 deformation of bus structure with passengers weight and luggage weight (front view) The result of translational displacement and 85

18 xvi deformation of bus structure with passengers weight and luggage weight (isometric view) The deformed geometry of rollover bar The design of ECE R66 bus superstructure The arrangement distance of rollover bar of the 93 Bus superstructure The dimensions of rollover bar The dimension of the rollover bar cross section 95

19 xvii LIST OF GRAPHS NO. TITLE PAGE The graph of bus structure velocity versus time 69 (for rollover simulation with bus structure only) The graph of bus structure kinetic energy versus 69 time (for rollover simulation with bus structure only) The graph of bus structure impact force versus 70 time (for rollover simulation with bus structure only) The graph of bus structure velocity versus time 71 (for rollover simulation with bus structure and passengers weight) The graph of bus structure kinetic energy versus 71 time (for rollover simulation with bus structure and passengers weight) The graph of bus structure impact force versus 72 time (for rollover simulation with bus structure and passengers weight) The graph of bus structure velocity versus time 73 (for rollover simulation with bus structure, passengers weight and luggage weight) The graph of bus structure kinetic energy versus 73 time (for rollover simulation with bus structure, passengers weight and luggage weight) The graph of bus structure impact force versus 74 time (for rollover simulation with bus structure, passengers weight and luggage weight)

20 xviii LIST OF SYMBOLS a = Acceleration of object d = Crumpling distance or travel distance F avg = 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

21 xix LIST OF APPENDICES NO. TITLE PAGE 1.1 The gantt chart of final year project The gantt chart of final year project The mass properties of carbon steel 107 (ASTM A500) square hollow section 2.2 Bus structure coordination The drawing of bus structure (3D) The drawing of bus structure (2D) The drawing of rollover-bar or pillar (3D) The drawing of rollover-bar or pillar (2D) The dynamic and kinematic analysis results of 116 bus structure simulated by ADAMS-View (Rollover Simulation with Bus Structure Only) 4.2 The dynamic and kinematic analysis results of 117 bus structure simulated by ADAMS-View (Rollover Simulation with Bus Structure and Passengers Weight) 4.3 The dynamic and kinematic analysis results of 118 bus structure simulated by ADAMS-View (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)

22 xx 4.5 The result of translational displacement and 120 deformation of bus structure (Rollover Simulation with Bus Structure and Passengers Weight) 4.6 The result of translational displacement and 121 deformation of bus structure (Rollover Simulation with Bus Structure, Passengers Weight and Luggage Weight) 4.7 The summary of overall results 122

23 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.

24 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 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 National Automotive Sampling System (NASS) and Crashworthiness Data System (CDS).