ELECTRIC BUS BUILDING PLANT

Over the past decade, India’s cities have been witnessing an increasing trend in motorization with deteriorating air quality, and there have been calls to promote public transport as a way out of this gridlock. It is in this context that electric buses can play a positive role, as there are several benefits associated with the shift from conventional diesel buses to electric buses in terms of reduction in local pollution, noise, and fuel consumption.

In spite of the many positive benefits related to the electric bus technology, certain challenges remain. Primary among these are costs and safety concerns. Currently, the Electric Vehicle (EV) technology is associated with significant capital costs, with the battery component constituting about half of the total manufacturing costs. Safety is yet another important parameter, and the biggest concern is that of a fire hazard. However, with a good Battery Management System (BMS), rigorous implementation of standard operating procedures, and customization of bus fleet, both safety and cost aspects can be effectively addressed. Electric buses have already been deployed on a large scale globally, and the technology is mature and evolving continuously.

INTRODUCTION
CATEGORISATION OF BUSES
(A) SCHOOL BUS:
(B) SLEEPER COACHES:
(C) TOURIST BUS:
LOW CAPACITY BUS INCLUDE –
MEDIUM CAPACITY BUSINCLUDE –
HIGH CAPACITY BUS
BUS BODY
COMPONENTS OF BUS BODY
(A) CROSS BEARERS
(B) VERTICAL PILLARS
(C) ROOF ARCH MEMBERS
(D) CANT RAILS
(E) WAIST RAILS
(F) SOLE BARS
(G) SEAT RAILS
(H) FLOOR RUNNERS
(I) ROOF RUNNERS
(J) OUT-RIGGER BRACKETS
(K) U” BOLTS
(L) A PILLAR
(M) FRONT OUTRIGGER MEMBERS
TYPES OF BUS BODY
1. NORMAL CONTROL BUS
2. SINGLE DUCKER
3. SPLIT LEVEL
4. DOUBLE DECKER
5. TWO LEVEL SINGLE DECKER
6. ARTICULATED BUS BODIES
PART NAME & LOCATIONS:
TYPES OF BUS BODY CONSTRUCTION
1. FRAME CONSTRUCTIONAL DETAILS:
2. DOUBLE SKIN CONSTRUCTIONAL DETAILS:
(A) INTERIOR PANELING:
(B) EXTERIOR PANELING:
TYPES OF BUS CONSTRUCTION
(1) CONVENTIONAL TYPE CONSTRUCTION:
THE FRAME SECTIONS ARE GENERALLY, USED
ADVANTAGE:
DISADVANTAGE:
(2) INTEGRAL BUS BODY (MONOCOQUE/UNIBODY) CONSTRUCTION
ADVANTAGES:
DISADVANTAGES:
USES AND APPLICATION
(1) PUBLIC TRANSPORT
(2) TOURISM
(3) STUDENT TRANSPORT
(4) PRIVATE CHARTER
(5) PRIVATE OWNERSHIP
(6) PROMOTION
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
(1) FABRICATION PROCESS OF STRUCTUE OF BUS BODY
STRUCTRE SECTION
STRUCTURE ASSEMBLY
(2) SIDE PAENLING & ROOF PANELING
(3) INTERNAL PANELING
4. PROTECTION TREATMENT AND PAINTINGS
PAINTING PROCESS
5. FITTING OF INTERIOR AND EXTERIOR COMPONENTS
6. MOUNTING OF BUS BODY TO CHASSIS
QUALITY CONTROL
(A)METAL TEATMENT
(B) BODY MOUNTING:
(C) FLOOR:
(D) ROOF STRUCTURE:
(E) SIDE STRUCTURE:
(F) PANELLING:
(G) CANT RAIL:
(H) STEP WELL:
7. TESTING:
TEST CONDITIONS
TEST PROCEDURE
FACTORS AFFECTING ROLLOVER:
(2) STABILITY TEST
(3) JOINT STRENGTH TEST
(4) WATER LEAK PROOFING TEST
(5) PREPARATION OF THE VEHICLE
(6) TEST PROCEDURE
(7) ACCEPTANCE CRITERIA
(8) PDI (PRE DISPATCH INSPECTION)
MARKET SURVEY
MARKET DYNAMICS
TRENDS
GROWTH DRIVERS
OPPORTUNITIES
GLOBAL BUS MANUFACTURING INDUSTRY 2012-2017
THE WORLD OF BUSES AND COACHES FOR 2012
GLOBAL BIGGIE’S LINE UP FOR INDIAN BUS MARKET
GLOBAL DEMAND FOR BUSES TO 632,000 UNITS IN 2016
MANUFACTURERS/SUPPLIERS
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
M.S. CHANNELS AND ANGLES
SUPPLIERS OF M.S. FLAT
SUPPLIERS OF M.S PLATE
M.S. PIPE
CR/BP SHEET
ALUMINIUM CHEQURED PLATE
DEGREASING CHEMICAL
PHOSPHATING CHEMICALS
METAL PRIMER
PAINT THINNER
COATING POWDER
ELECTRICAL HARNESS
SUPPLIERS OF AUTO LIGHT
MIG WELDING WIRE ELECTRODE
FIRE EXTINGUISHERS
AIR CONDITIONER
SUPPLIERS OF SEAT
SUPPLIERS OF SPEAKER
SUPPLIERS OF PLANT AND MACHINERIES
PUNCHING PRESS
POWER PRESS
SHEARING MACHINE
ROLLING MACHINE
BENDING MACHINE
CNC PLASMA CUTTING MACHINE
PNEUMATIC RIVETING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
WELDING MACHINE
MIG WELDING MACHINE
PAINTING BOOTH
CHROME PLATING PLANT
PHOSPHATING PLANT
POWDER COATING MACHINE
METAL TESTING MACHINE
PRECISION MEASURING TOOLS
ELECTRICAL MEASURING INSTRUMENTS
EOT CRANES
POWER TRANSFORMERS
ELECTRICAL PANEL
COOLING TOWER
EFFLUENT TREATMENT PLANT
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSORS
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
SHOT BLASTING MACHINE

APPENDIX – A:

1.      COST OF PLANT ECONOMICS
2.      LAND & BUILDING
3.      PLANT AND MACHINERY
4.      FIXED CAPITAL INVESTMENT
5.      RAW MATERIAL
6.      SALARY AND WAGES
7.      UTILITIES AND OVERHEADS
8.      TOTAL WORKING CAPITAL
9.      COST OF PRODUCTION
10.      PROFITABILITY ANALYSIS
11.      BREAK EVEN POINT
12.      RESOURCES OF FINANCE
13.      INTEREST CHART
14.      DEPRECIATION CHART
15.      CASH FLOW STATEMENT
16.      PROJECTED BALANCE SHEET