Modern Tools Make Reverse Engineering Easier

The paper presents the usage of the optical measuring system and computer aided design in the process of converting a city bus into a panoramic bus. The conversion goal is to enable easier transfer of tourists and city sightseeing. This intervention requires the removal of the solid roof from the vehicle body structure and the addition of two security frames (roll bars). Such a modified bus must meet certain regulations regarding the public transportation and passengers’ safety in the event of the bus rollover. The modified body structure and security frames must be strong enough to withstand the static load equal to the maximum allowable total mass of the vehicle. Based on body structure strength regulations, CAD and FEM models were created. A strength analysis of the modified body structure showed that stresses in such a construction would not exceed the allowed stress for a given material. In addition to the FEM body structure analysis, the calculation of the roll bar stability was made, resulting in a conclusion that no stability loss could occur and that the security frames or body structure will not fracture.