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Bus manufacturing process

Special Technical Features in our Bus Body Construction

Kamthe Auto Agencies (Pune) kamtheauto_katraj@rediffmail.com

ADVANTAGE OF DESIGN PARAMETER


S.No i ii iii iv v vi FEATURE OVER ALL LENGTH WHEEL BASE REAR OVER HANG FRONT OVER HANG OVER ALL WIDTH OVER ALL HEIGHT A B C D E F WT 50LWB 7348mm 3940mm 2364mm 1044mm 2100 mm (MAX) 2725mm ZT54E D ELWB 8660mm 4760mm 2856mm 1044mm 2100 mm (MAX) 2725mm

Kamthe Auto Agencies (Pune) kamtheauto_katraj@rediffmail.com

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

Kamthe Auto Agencies (Pune) kamtheauto_katraj@rediffmail.com

Advantages of Our Processes Over Conventional.


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.

Kamthe Auto Agencies (Pune) kamtheauto_katraj@rediffmail.com

Advantages of Our Processes Over Conventional.


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

Kamthe Auto Agencies (Pune) kamtheauto_katraj@rediffmail.com

Advantages of Our Processes Over Conventional.


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

Kamthe Auto Agencies (Pune) kamtheauto_katraj@rediffmail.com

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

Kamthe Auto Agencies (Pune) kamtheauto_katraj@rediffmail.com

Rolling Process
Panel Rolling Machine.

Kamthe Auto Agencies (Pune) kamtheauto_katraj@rediffmail.com

Structure Welding
Welding being done in proper fixtures

Kamthe Auto Agencies (Pune) kamtheauto_katraj@rediffmail.com

Baking Oven

Kamthe Auto Agencies (Pune) kamtheauto_katraj@rediffmail.com

Shower Test
A 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.

Kamthe Auto Agencies (Pune) kamtheauto_katraj@rediffmail.com