CLASSIFICATION OF COUCHWORK 1

SUB: VEHICLE SAFTEY AND REGULATIONS

SUB CODE: 21AU63

MODULE – 1

INTRODUCTION:
Coachwork simply refers to the body of a vehicle. This applies to cars, buses, trucks, motorcycles, and even
horse-drawn carriages! It essentially encompasses everything on the outside of the vehicle excluding the
chassis (the frame that holds everything together).

STYLING FORMS:
Types of Car Bodies
[Link]
[Link]
[Link]
[Link] / sedan
[Link] car / station wagon
[Link] car
[Link]
[Link]-roader
[Link] utility vehicle
[Link] -purpose vehicle / minivan
[Link] / campervan
[Link] up
[Link]
[Link]

1. Micro Car:
These vehicles have engines under1.0 litre, and typically seats for only two passengers

2. Hatchback:
A hatchback is a type of car which has a sloped back and a rear door that swings upwards when
opened. Hatchbacks have as hared passenger and cargo area

3. Lift back:
A lift back is marketing term for a hatch back, where opening area is more sloped and longer and
is lifted up to open, offering more luggage space

4. Saloon car / sedan

Is a passenger car with separate compartments for engine, passenger and cargo. It is one of
the most common car body styles, It has fixed roof that is full height up to the rear window.

5. Estate car or estate / Station wagon

Is an automobile with its roof extended rear ward over a shared passenger/cargo area with access
at the back via a third or fifth door Station wagons can change their interior by folding-down rear seats

6. Sport cars
Are designed to look and feel "sporty", offering the motorist more connection with the driving
experience, while providing the comfort of luxury vehicles. It has usually 2 seats with two door designed
for performance at high speeds.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 2

7. Convertible:
These models are provided with windup windows and folding roof. Also known as a cabriolet or
roadster

8. Off road vehicles, or off-roaders

Are sometimes referred to as an overland or adventure vehicle, is considered to be any type of
vehicle which is capable of driving on and off paved or gravel surface. It is generally characterized by
having large tires with deep, open treads, a flexible suspension, or even caterpillar tracks.

9. Sport Utility Vehicle(SUV):

Sport utility vehicles are off-road vehicles with four wheel drive and off-road capability. SUVs,
use a body-on-frame design. That means the frame and body are built separately and joined together
during the manufacturing process. These truck-based vehicles are generally more rugged and can be
used to haul larger payloads

10. Multipurpose (MPV) / Minivan

Is a type of van designed for personal use. Minivans are typically either two-box or one box designs
for maximum interior volume. It has rear side windows.

11. Van, camper , RV, minibus:

A van is a kind of vehicle used for transporting goods or people. Depending on the type of van, it
can be bigger or smaller than a pickup truck and SUV, and bigger than a common car

12. A campervan/camper/caravanette:
Is a vehicle that provides both transport and sleeping accommodation.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 3

13. A pickup / pick-up / pickup truck

Is a light motor vehicle with an open-top, rear cargo area (bed) for transportation of goods.

14. Limousine
It is a luxury car. They are longer than regular cars. The front and rear wheels are far apart. A
limousine may have security features such as bullet proof glass. It is usually provided with a partition
between the driver and the passengers. Cushioned seats, air conditioning cooling glasses etc. are the other
features of this model.

15. Coupe:
A Coupe is car which are often sporty variants of saloon or hatchback styles, with doors generally
reduced from 4 to 2 and a close – coupled interior.

COACH AND BUS BODY STYLE:

BUS BODY LAYOUT:

1. Entrance doorway skirt panel

2. Skirt panel front of front N/S wheel arch
3. Skirt panel rear of front N/S wheel arch
4. N/S main side panel Bay1.
5. Air filter access cap
6. N/S main side panel Bay2.
7. Skirt panel.
8. Spare wheel access flap.
9. N/S main side panel Bay3.
10. Skirt panel front of rear N/S wheel arch.
11. N/S main side panel Bay4.
12. Rear skirt panel, N/S.
13. N/S main side panel , Bay 5.
14. Pillar capping between Bay1 & entrance door.
15. Pillar capping main pillars.
16. Roof panel Bay1.
17. Roof panel Bay 2.
18. Roof panel Bay 3.
19. Roof panel Bay 4.
20. Valance panel for spare wheel access flap.
21. Valance panel.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 4

22. Valance panel for air filter access flap.

23. Front skirt panel O/S.

24. Main side panel below driver’s signalling window O/S.
25. O/S main side panel Bay 1.
26. Skirt panel rear of front O/S wheel arch.
27. O/S brake gear access flap.
28. Valance panel for O/S brake gear access flap.
29. Valance panel.
30. O/S main side panel Bay 2.
31. Skirt panel front of rear O/S wheel arch.
32. O/S main side panel Bay 3.
33. O/S rear skirt panel.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 5

34. O/S main side panel Bay 4.

35. Main side panel below emergency door.
36. Emergency door main side panel.
37. Pillar capping between emergency door and Bay 4.
38. Emergency door, top rail capping.
39. Emergency door, shut pillar capping.
40. Emergency door, hinge pillar capping.
41. Water bottle flap.
42. Fuel filter flap.
43. Header tank flap.
44. Electrical flap.
45. N/S rear pillar capping.
46. O/S No 1 pillar capping.

Terminologies:

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 6

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 7

• ‘Cant rails’ are structural members that connect two body sections above the window section.
• ‘Waist Rails’ are structural members that connect two body sections below the window section.
• ‘Seat Rails’ are structural members running along the lateral walls and provide support for seat
mounting.

CLASSIFICATION OF BUSES
Passenger carrying buses are classifies based on:

1. Distance travelled by the vehicle

2. Capacity of the vehicle
3. Shape and Style of the vehicle

Distance travelled by the vehicle:

• Mini bus
• Town bus
• Suburban bus
• Long Distance Coaches
• Touring Coaches
• Midi bus

1. MINI BUS:

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 8

• It should have a seating capacity upto 25.

• It built on light duty truck chassis.
• It has front mounted engine and rear axle drive.
• It has soft and comfort suspension.
• It has reasonably comfortable seat.
• It has fairly small entry platforms.

2. TOWN BUS.

• These buses are used for a short distance of about 20kms.

• They are provided with large number of standing places two places, wide doors with large entry and
exit platform and hard seats covered with durable plastic materials.

3. SUBURBAN BUS

• These buses are used for a distance of about 40 to 50 kms. They usually have reasonably comfortable
seats.
• Fairly small entry platform for the extra space can be used for luggage and extra standing passengers.
• Usually one door is sufficient for this type of operation.

4. LONG DISTANCE COACHES

• These buses are used for a distance of about

200 kms and above. They have comfortable seats
with under floor luggage space and roof racks for
large items of luggage.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 9

5. TOURING COACHES

• For longer distance touring coaches, very comfortable reclining seats are used.
• Toilets, air conditioners, TV, etc are provided.
• Additional windows in the roof are used to improve visibility for the passengers.
• Thermal and acoustic insulation is usually elaborate and spacious luggage compartments are
provided under the floor and on the roof

6. MIDI BUS
• A midi bus is a classification of single-decker minibuses which are generally larger than a traditional
minibus but smaller than a full-size single decker and can be anywhere between 8 metres and 11 metres
long.

Based on the capacity of the vehicle

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 10

Based on Shape and Style of the vehicle

• Classic type
• Single Decker
• Double Decker
• Split‐level bus
• Two‐level single Decker
• Articulated bus

1. Classic type

• The Classic or normal control bus has the engine in front of the passenger carrying compartment.
• This design, which was almost universal at one time, has practically disappeared and is mainly of
historical interest.
• Low ratio of useful length to overall length.
• It also has a high tare weight and poor aerodynamic shape.

2. Single Decker

• In this type of buses engine is mounted either inside or below the driver’s cab enabling additional
length available for more seats and a better angle of vision. - Such buses may have one or two doors.
- Many single deck models have seating capacity of fifty two which in city buses is reduced to have
more space for standing. This enable transportation of more passengers for short duration.

• The full‐length bodywork, i.e. single deck bus or coach is almost universal today as this layout
eliminates all the disadvantages of classic type.

3. Double Decker

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 11

• These buses have a greater number of seats for a given overall length than a single Decker but
stability is not so high as for the single Decker.

4. Split‐level bus

• An intermediate solution between the two is the split‐level [Link] layout has more seats than a
single Decker and more stability than the double Decker.
• However, owing to the small number of variations that can be made from this basic design, it has
not been widely accepted.

5. Two‐level single Decker

• Two‐level single Decker has been used for luxury coaches.

• This layout provides good forward visibility for all passengers, good luggage space and easy
installation of an under‐floor or rear engine.
• Again this type is only made for special orders, as it is not easy to make derivations from the same
body shell.

6. Articulated bus

• ‘Articulated Vehicle / Bus’ means a vehicle which consists of two or more rigid sections which
articulate relative to each other; the passenger compartments of each section is interconnected by an
articulate section allowing free movement of passengers between them.
• Bodies for very large coaches or in particular, city buses are often made in two parts because of axle
load limitations. The rear portion is articulated to the main vehicle by a covered pivot allowing easy
access between the two sections.
• A bi‐articulated bus or double articulated bus is an extension of an articulated bus in that it has three
passenger compartment sections instead of two.
• This also involves the addition of an extra axle. Due to the extended length, bi‐articulated buses tend
to be used on high frequency core routes or bus rapid transit schemes rather than conventional bus
routes.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 12

Bus body Regulations:

LIST OF COMMERCIAL VEHICLES IN INDIA

This list of commercial vehicles in India can give you a perfect choice for your operations. Along with this,
you can choose one of them according to your needs and demands. We come with this list so that you can
know all about some categories, which are:

1. Tippers
The first commercial vehicle on
the list is tipper. Tipper is also known
as a dump truck, dumping
truck, dumper trailer, dumper lorry.
This type of commercial vehicle is
used to transport materials (such as
dirt, gravel, or demolition waste) for
construction and coal.
Generally, tippers are used for
transporting materials in different
sectors such as construction, industry,
farming and many more.

2. Trucks
• The second commercial vehicle
in the list is trucks, designed to
transport loads or cargo, carry
special payloads, or perform other
useful functions. The types of trucks
vary widely in size, configuration
and power. Trucks can be large and
strong to handle all the challenging
commercial applications.
• In addition, they may be
configured to be mounted with
specialized equipment, such as suction
excavators, refuse trucks, concrete mixers, and fire trucks.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 13

3. Tractor Trucks
The third commercial vehicle on the list
is tractor trucks which are also known as
trailer trucks. They are a combination of a
tractor unit and one or more trailers for
freight. A semi-trailer attaches to the tractor
with a type of hitch called a fifth wheel. A
trailer is an unpowered commercial vehicle
that is linked to a powered vehicle. It is mainly
used to transport materials and goods.

4. Mini Trucks

The fourth one on the list of commercial

vehicles types is mini trucks, used for small
freight businesses. Mini trucks, also called
micro-trucks, are small but practical light
trucks, available in either RWD or 4WD
versions. These vehicles find their use in
intra-city low tonnage cargo delivery, such as
postal and courier services or home delivery
of equipment from dealer to the customer, i.e.
light loads over short distances.

This range can broadly be described as a sub 1000cc engine and weighing less than 3.5 tonnes. The segment
competes with the existing three-wheeler segment based on cost, durability and new pollution control laws.
Mini trucks are suitable for small intra-city deliveries that ply on narrow village roads, long highways carrying
small heavy loads or even heavy cargo.

5. Pickups

A pickup is an essential truck with a separate

side/cab and an open rear section. Pickups
rely on trucks, which are made of two pieces
and have more space. A pickup truck is a
vehicle type designed to move things. The
rear of the truck is open, as in some different
types of trucks. It is exceptionally wonderful
for its small size. Pickup trucks come in
various sizes and shapes.

TERMS USED IN BODY BUILDING CONSTRUCTION IN VEHICLE:

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 14

a) Angle of Approach:
An approach angle is the maximum upward angle of an inclined surface that your 4WD vehicle drives
over. The bumper design and its overhang over the axis; rounded bumpers and higher ground clearance
will give your vehicle a better chance of making it up steeper surfaces.

b) Angle of Departure:
Push the approach angle to the back of your vehicle and you have the departure angle. Referring to the
angle of the surface you’re departing from, this angle is also determined by bumper choice and rear
tire size.

c) Ground Clearance:

Ground clearance is the least distance between the lower end of the vehicle body or chassis and the
road. It defines the lowermost part of the vehicle in comparison to the ground.

d) Cross bearers
Cross bearers are U-shaped members that support the
floor of a vehicle, located on the longitudes or either
chassis member. They are part of the vehicle's interior and
provide structural support for the instrument panel, safety,
and noise and vibration. The ends of the cross car beam
are mounted to the firewall and body walls, making it the
backbone of the instrument panel.

e) Floor Longitudes:
The main longitudinal members of a vehicle's body are the
main stress members. The body sill is a metal plate
directly below the bottom of the doors that supports the
floor and can combine the floor and body.

f) Posts:
A car stands on six pillars or columns, sometimes called
posts. Different types of cars also sport the D and E pillars.
You can identify all the three pillars separately if you look
at the vehicle from a side profile. Pillar A is the sloping
pillar that supports the windshield.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 15

g) Seat Rail:
A seat rail is a metal track that is mounted to the floor of a vehicle and the bottom of the car seat. It
allows the seat to be moved forward and backward to adjust legroom for passengers.

h) Waist Rail:
A waist rail in a car is a structural element that runs horizontally along the side of the vehicle, typically
around mid-body height.

i) Cant Rail:
A cant rail in a car is the horizontal trim piece that runs along the top edge of the car's side, where the
roof meets the vertical window pillars (A-pillar, B-pillar, and C-pillar).

j) Roof Stick:
As mentioned before, “roof stick” could be a slang term for a car or bus antenna, especially a long,
vertical one mounted on the roof.

k) Roof Longitude:
Cars don't have a designated "longitude" on the roof. Longitude refers to directional lines running
vertically on a globe (north-south) and isn't applicable to car roof sections.

l) Rub Rail:
A rub rail on a vehicle is a long, narrow strip of material attached to the side of the vehicle, typically
running along the lower portion.

m) Truss Panel:
In the context of vehicles, a "truss panel" isn't a widely used term. Car bodies are built using different
components and structures, and "truss" typically refers to a specific engineering design principle.
Here's why:
• Truss Structure: A truss is a framework made from connected elements (beams) that form
triangles. These triangles help distribute forces efficiently and provide strength with minimal
material.
• Car Body Construction: Car bodies are typically constructed using a combination of stamped
steel panels, beams, and pillars. While some beams might be arranged in triangular shapes for
strength, they wouldn’t be referred to as a complete “truss panel” in standard terminology.

n) Wheel arc structure:

The wheel arch, also known as the wheel, well or fender, is
the curved or flared area of a vehicle's bodywork that
surrounds the wheel and tire.

o) Wheel arc:
The arch is called 'Wing' in Britain English. In German 'mud wing'. And in American English its
'fender'. This is the modern style of saying.

p) Post Diagonals:
The diagonal pillar in a car's side view is the A-pillar, which is usually at a 40 degree angle from the
horizon. The A-pillar's angle and straight shape give the car a strong, aerodynamic body and a front
door of a suitable size.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

CLASSIFICATION OF COUCHWORK 16

q) Gussets:
Each gusset is attached at the outside of an interior of the vehicle to an upper wall and a side wall of
each damper base, and typically has an upper wall combined with a bottom face of the upper wall of
the damper base; a side wall fastened to an outer face of the side wall of the damper base.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.