Project outline: a new brand of NOE Design2life’ coach in innovative production technology with the selection of materials.

Project - production of special coaches of the new BRAND NOE Design2life' in our industrial design - design, innovative selection of materials and manufacturing technology. In the innovative selection of the machine park in the new plant - mainly CNC machines, the technological line in the sustainable development of the production itself, but also the use of the future vehicle in harmony with the natural environment using electric motors, in the Hydrogen type alternative guaranteeing zero CO2 emissions to the environment. With a reduced weight of at least 30% of the bus in the analogy of the size of the coach, made of plastic PC body, a few other plastics and chassis – with a self-supporting structure conventionally called "skull" made of CF and AL. In a very luxurious and comfortable version for transporting passengers in the VIP Class, Covi-Travel and Special Bus segments. 

Already at the very beginning of the visionary look of the design stage, I decided to adopt the most demanding techniques for creating visualizations of the future product using, among others: Blender, Pchotoschop programs using other, even more demanding ones. In the next phase, we recommend using specialized 3D CAD software, the most expected would be the choice of CATIA V5.6 (the most expensive choice, but the most effective), in the alternative can be used AUTODESK Alias, also Auto CAD. For those who do not know, such a choice reduces the costs of producing technical documentation necessary for implementation into production as well as creating the documentation itself for the purposes of securing traditional design methods in a technical drawing. And they are 2/3 smaller than traditional methods of creating technical documentation. This is the main reason for the implementation of this highly technological method of supporting the Studio – Design2life'. But also indirectly allows you to create a faithful visualization of the future product for promotion in gaining potential financial investors for the planned venture and future investments with a greater scope. It brings the idea of the product closer and convinces a group of interested parties to make financially important decisions or reasons for further investment. After this phase, we recommend: Adopting the concept of creating models (from industrial clay) on a scale of 1:10 and 1:4, which will allow the assessment and verification of shapes before the final prototyping of the target product before the product. Not always the design even in 3D visualization is acceptable "on the march" you should consider such a serious design in the natural environment and in real time. This is what the best manufacturers of passenger cars do, or in aviation even necessary and fundamental action.

In the assumed production cycle, starting prototyping, we break all stereotypes. We eliminate: the use of glass, liquid resins, glass mats, granules, steel and the final painting of the car body – which makes the emission of toxic components into the environment so far. We are going to build the safest bus in the world. Which will provide better resistance to breakage, thanks to which it will reduce (in the event of an accident) - the risk of injury. It will also protect against burglaries due to the extremely selected - durable material. The transparency of the selected materials will be classically clean, providing excellent visibility to the passengers of the vehicle as well as comfortable work of the driver, who in the exposed design will acquire a very horizontal visibility, which is the most horizontal on the passenger deck. There will also be benefits of better damping, less abrasion and a higher degree of recovery of secondary materials. And in the case of, for example, side collisions, the selected materials will absorb energy very efficiently. But they will also ensure the highest available level of flame retardancy - a high non-flammable class (at the time of possible ignition of the coach) they will meet many standards in the field of toxic combustion products, specifying the permissible emission of carbon monoxide, hydrogen cyanide, sulfur dioxide and hydrogen sulfide. And also very low smoke emissions with a low specific gravity, without the use of bromine and chlorine compounds additives, thus meeting the requirements (ROS) in the new EU directives, and other environmental regulations – EC standards. While maintaining excellent mechanical properties, improved plasticity and strength.

After accepting the design of the body, the body of the coach, the outer and internal plating of the achieved technical documentation in 3D CAD, the process of switching to CAM/CAE/MES support software with programming of CNC machines of selected shapes will begin. In the initial phase, a CNC 5 machine will be necessary – a numerically controlled CNC axial machine to create molds from material (for a prototype and a short series – with UREOL and Aluminum for serial production). By the way (for our one or even two prototypes, (earlier - demonstration elements we will use external companies), so that the initial version will be made, we will process it to the state of use in the further process). 

After their production, it will be necessary to thermoform solid polycarbonate (PC) plates into the expected solid shape, using another necessary CNC machine Termo numerically controlled molding machine. These processes will be supported in the process of manufacturing parts and materials – CAM and CAE programming of the above-mentioned numerically controlled machine tools. With the production process in the technology submitted by the Originator to secure industrial property rights. The use of such devices in the process of building the prototype sheathing will allow the Originator to achieve vacuum lamination of large surfaces permanently connected to each other with the latest in the world available adhesives for plastics. With the merging of metal elements mainly allowing for stronger twisting of parts with others. This and a few other innovative solutions (it will give a chance to obtain at least 5 patents on the world stage).

The use of solid polycarbonate (PC) boards with a thickness of 3 to 5 mm for plating with large areas does not give adequate rigidity, which is why we have adopted "like bending in an arc" the expected shapes of the plating - profiles in the shape of the letter "S" to stiffen the powerful planes of the coach, but we also definitely introduce the need to fill the space between the outer plane of the body and the inner, PU foam in the "Greensir" spray technology. The proposed additional reinforcement of thermoformable products in the new "Greesir" system will allow the production of an element with very good mechanical, thermal insulation and strength properties and will provide effective sound insulation for travelers. Maintaining perfectly mechanical properties, improved plasticity and strength with extremely unlimited design, shape of the final product. And what is most interesting, this choice will eliminate the operation of coating with paint in the production process, which will be dyed in any color as part of the technology of manufacturing the components of solid boards in Color Xpress technology by the supplier manufacturer (even before the thermoforming process), The effect of reinforcement in the new plant will be obtained at a separate workplace in a separate separate place of the closed cabin, operated by the operator of the "Greensir" system. Such the above-mentioned modern machines will allow the production of structural elements of the body and materials of coach equipment. The use of the "Greensir" system by the Applicant will be another necessary investment in material assets. 

I propose another development strategy for the production of a supporting structure called "skull" – unfortunately, it will be a typical manufactory, which from the beginning to the end we will want to take care of it personally (yes, in cooperation with scientific institutes for the verification of strength calculations). Because it will be made of Carbon Fibre CF, but on a previously certain specifically made steel tool matrix. I do not want to write about it for reasons of securing my own know-how at this stage. The first front and rear part of this structure will be made of CF, while the middle one will be made of aluminum in the shape of a "drawbar". Omitting the side posts, which I plan to make also with CF. These parts will be twisted together, not welded together or in the option of sort of stuccoing CF elements from AL., also specifically to discuss - not writing about it. These will be the most innovative solutions using various CF plastic mixtures. It should be remembered that I am also a boatbuilder and I have always been interested in boats, mainly catamarans and I know that they are the closest modern solution used in space or aviation. Their solution will in a sense be implemented in the production of our future NOE Design2life coach. 

It should be remembered that we have now entered a certain global crisis in supply chains and high prices of steel in particular, so all the more so in my case the replacement of steel and even aluminum (for plating) with plastics is the most justified choice in economic and ecological terms, and certainly more sustainable production.  The use of the chassis – with a self-supporting structure conventionally called by us "skull" made of CF, AL will create huge reserves (up to 50% reduction in its weight in the analogy of steel construction) weights that are important for the installation of electric motors with batteries (heavier solutions than in the tradition of currently used internal combustion engines). For this reason, we had to find weight reserves in the body of the coach so that the stored energy in the batteries, or H2, was protected for longer distances.  Our coach will reach the largest dimensions in relation to those we know in the world. , the largest two electric motors in non-standard wheels in the rear single axle of the vehicle, achieving the greatest possible power, but also distance, thanks to freedom and new space for batteries reaching up to 1000 km for the next charge. And at the same time it will achieve a weight reduction of 30% to 50% of the bus in analogy, thanks to the PC body used in the production of plastics, reinforced from the inside with PU foam plating, a few other newest plastics available on the market. According to a comprehensive description of the adopted innovative technology for the implementation of mainly the Covi-Travel- NOE Design2life project ...

It should be remembered that we have now entered a certain global crisis in supply chains and high prices of steel in particular, so all the more so in my case the replacement of steel and even aluminum (for plating) with plastics is the most justified choice in economic and ecological terms, and certainly more sustainable production.  The use of the chassis – with a self-supporting structure conventionally called by us "skull" made of CF, AL will create huge reserves (up to 50% reduction in its weight in the analogy of steel construction) weighing that are important for the installation of electric motors with batteries (heavier solutions than in the tradition of currently used internal combustion engines). For this reason, we had to find weight reserves in the body of the coach so that the stored energy in the batteries, or H2, was protected for longer distances.

Our coach will reach the largest dimensions in relation to those we know in the world. , the largest two electric motors in non-standard wheels in the rear single axle of the vehicle, achieving the greatest possible power, but also distance, thanks to freedom and new space for batteries reaching up to 1000 km for the next charge. And at the same time it will achieve a weight reduction of 30% to 50% of the bus in analogy, thanks to the PC body used in the production of plastics, reinforced from the inside with PU foam plating, a few other newest plastics available on the market. According to the comprehensive description of the adopted innovative technology for the implementation of mainly the Covi-Travel- NOE Design2life' project, which will additionally have a unique arrangement of the passenger deck in a specific single cut, line, design of asymmetrically spaced seats with four anti-covid protection of air vents, air exchange described in a separate study.

The use of a double axle at the front (for load balance for 15 m of bus length) and a single rear axle with very large wheels (1.35 m of rim inner diameter) is a very bold solution: designer, in order to increase driving comfort and, above all, to install large two electric motors located opposite each other. Which excludes the need to install a minimum of four, which is currently the custom of manufacturers to obtain the right propelling power. Powered by batteries integrated into one in the location under the floor of the luggage compartments of the middle and rear of the bus. With this solution, we will reduce the center of gravity of the bus mass to the maximum, which will be the highest safety factor.

The advantage of investing in your own technological line is the ability to quickly make the expected elements of the body and equipment of the coach from various elements without significant participation of the human factor. Current coach manufacturers use typical materials in their technological processes in the form of: steel, aluminum, polyester resins, acrylic, polymer resins and glass. Without paying special attention to the issues of non-flammability of the materials used in the production due to the quite liberal requirements of the EU Directives as of today (this is decided by lobbyists), as well as the weight of the coach is not very important to them, if they exceed it, they only indirectly react and, for example, move the "raised air conditioning" from the rear part of the coach to the front in order to reduce the pressure on the rear axle creating the proverbial "hydrocephalus" on the coach. This change has nothing to reduce the weight of the coach, but only allows you to fit into the standards of pressure on the rear axle of the coach this attitude to the problem does not guarantee fuel economy. The originator or applicant took care of these issues in his concept in a comprehensive and convincing way. And he insists on building a new plant, or department in an existing factory, where a whole specific production line for serial production will be built. It is more profitable. Rather, this should be obvious and understandable by all. It should be remembered that we have now entered a certain crisis in the supply chains and the high prices of steel in particular, so all the more in my case the replacement of steel and even aluminum (for plating) with plastics is the most justified choice in economic and ecological terms, and certainly more sustainable production.

Adding to the issue of environmentally friendly recycling of used or proposed materials for production. My project is based on replacing the traditional materials of the exterior and interior of the coach with polycarbonate materials, especially from solid PC boards. In the automotive industry in the coach production segment, these materials are not yet used today. All the more so they are not used so far in the technology of thermoforming of body parts, interior equipment and glazing of the coach. The use of polycarbonate materials from the top shelf of plastic availability (with varying degrees of lightness, which are guaranteed by suppliers in the world, or hardness, also not flammability used depending on their purpose in the coach under construction). Their use in the production process of the coach is an innovative solution. Reducing primarily the own weight of the coach by a minimum of 30% (the size adopted in the analogy), and thus increasing the range for the next charge for the adopted version of the coach powered by electricity, or in Hydrogen technology to choose from. Observing the market, but also the achievements of Polish engineers, the balance is tipped to the choice of the H2 version, so are visible these trends in power supply in H2 in Ireland, USA, China, Australia, especially for heavy trucks of sawmills and also long-distance buses in trace quantities (at this point we could expect thanks to you - to be at the forefront).

Developed by the Originator, owner of know haw Miroslaw Krutul