Bus,truck manufacturing process

Bus manufacturing process

Special Technical Features in our Bus Body Construction

Kamthe Auto Agencies (Pune) [email protected]

ADVANTAGE OF DESIGN PARAMETER

S.No FEATURE WT 50LWB ZT54E D ELWB

i OVER ALL LENGTH A 7348mm 8660mm

ii WHEEL BASE B 3940mm 4760mm

iii REAR OVER HANG C 2364mm 2856mm

iv FRONT OVER HANG D 1044mm 1044mm

v OVER ALL WIDTH E 2100 mm (MAX) 2100 mm (MAX)

vi OVER ALL HEIGHT F 2725mm 2725mm


Advantages of Our Processes Over Conventional.

Our Process We use rolling process for hat

sections & C-channels

We use rolling for our outer panel and roof panel sheets. The strength of the sheet is increased without affecting its properties. The sheet is with smooth edges and a uniform structure throughout gives proper strength .

Welding, we use MIG welding and all of the welding is done with help of jigs and fixtures, for uniformity & productivity. Welding defects are minimum

Conventional They are using square tubes,

which are generally not painted from inside and get rusted faster & Joint of Tube gives away.

Generally no process is done, the sheet is as it is sheared and riveted, thus having sharp edges and non uniform structures on the surfaces

Generally ARC welding without any welding fixtures and jigs are used


Our Process We are using hat sections with

C-Channel boxing of thickness 2mm and 1.6mm respectively, which have section modulus about ‘x’ axis is 7.53 X 103 kg/mm2 and about ‘y’ axis is 4.9 X 103 kg/mm2. That is it have much more strength as compared to similar thickness tube.

We use single rolled sheet, which is welded to the structure for outer panel. We do not use rivets

Conventional The square tube sections used

conventionally are 40X40X2mm which is having section modulus of 4.2X103

kg/mm2 about ‘x’ axis and ‘y’ axis, which is very less.

Mostly the sheets used are riveted with structure, which doesn't look good and tend to loosen after some time, due to vibration.



Our Process Our bus is having an

aerodynamic shape, which cuts air drag and improves fuel efficiency

We are pretreating the Structure and the painting is done in the specialized paint-booths, which results in longer life.

Conventional The designs are mostly

not aerodynamic.

Generally the painting is done without much of pre-treatment



Our Process We are making bodies on the

trolleys and subsequently mounting on the chassis, after painting. which results in faster and uniform production. Welding and other processes does not affect the chassis for stresses.

We use PU Paint for our buses which have 500 hrs of salt-spray life and 80% of the gloss retention after 2 years. And 1000 hrs of Salt Spray for Export Buses

Conventional Mostly the bodies are

made and painted on the Chassis itself



Rolling Process Rolling and press being used for outer panel sheets, hat

sections and c-sections


Rolling Process Panel Rolling

Machine.


Structure Welding Welding being done in proper fixtures


Baking Oven


Shower TestA Shower test is done for every vehicle both before painting (for Roof Leakage Check), and after Paint and fitment of Window Frames, Glasses and Doors, to check over all leakage.


Bus,truck manufacturing process

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