Over the course of a long bus service life, drivers press buttons to open the doors tens of thousands of times. This continuous use results in a lot of wear and tear. As the years go by, a smooth, stained surface forms around the buttons. But this is not the case with the new Setra MultiClass 500 LE: In this case, the component is subjected to an electric current using an anode. The result is a slightly rough, fine-grained finish known as the EDM grain finish. Durable, resistant to dirt, indestructible.

The typical Setra quality is reflected in many details of the new intercity buses, the grain on the instrument panel is just one example of many. “We have set ourselves the standard of providing a surface quality on a par with the automobile industry,” Vincent Thess explains. He is responsible for features such as the MultiClass 500 LE's cockpit design.

For the first time, developers and designers have used VR glasses at a very early stage. In collaboration with the University of Ulm, drivers of all sizes took their seats one after the other in a virtual cockpit, built up in a virtual space constructed from digital data. The objective: a driver-friendly workplace offering the best ergonomic operation.

“That was certainly very useful,” as Vincent Thess summarised the process. “We received many suggestions that we implemented.” For example: the roller sunblind was initially difficult to reach, so it is now operated electrically. We created more space for the knees and even optimised the attachment of coat hooks and coat hangers. Small details that make a big difference in everyday life.

The cockpit of the new MultiClass 500 LE is dominated by a conservative design, it is a workplace after all. Three variants are offered: there is Cockpit City for use in the city in accordance with the requirements of the Association of German Transport Companies (VDV). Then there is Cockpit Basic at touring coach level for intercity operations. And finally, the Basic City Cockpit if companies order a double-width, inward-swinging door at entrance 1 that requires more space at the front end.

“Whenever we integrate design, the goal is functional,” Thess stressed. And it can clearly be seen that the basic shape of the three cockpits can be broken down to a horizontal line – Thess talked of a “plimsole line” - and an elegant curve that opened up into a storage space.

“We have created some tangible value,” he added. This is also evident, for example, from the Kässbohrer brand badge, the “rolling K” on the steering wheel. Its engraving is reminiscent of a luxury watch – something that gets the drivers' hearts beating.

As part of the next step, Daimler Buses tested how this heart beats in the real world. This is called Pulse Check. Test engineer Andreas Türk explained: “We look at the vehicle from the customer’s perspective.”

For this purpose, we simulate a typical working day of a driver in phase 1. A team consisting of designers and test engineers meets early in the morning to set off in the vehicle. The door is opened, the light is switched on. Drivers must find the space for their typical equipment. For this purpose, test engineers have developed a driver package: a large bag, glasses, a box for food, drinks, coat, mobile phone, valuables, etc.

The phase 1 Pulse Check includes typical driving situations: using storage spaces, checking visibility, reaching out of the window to a ticket machine at the toll booth, and using all the controls for heating, ventilation, air conditioning, the tachograph, or entertainment systems. “We are leading the way,” said Andreas Türk, identifying potential improvements at an early stage.

Türk’s colleague Dietmar Denzel provided some examples: “During practical testing we found that a screen print on the front of the driver’s window disrupted the view into the outside mirror when it was directly attached to the A-pillar. So we just got rid of it!"

With the City Cockpit, the control panel for the heating, ventilation, and air conditioning system is located on the left in the window panel – easy to operate, but difficult to see. Problem solved: Now there are appropriate displays within the instrument cluster.

Next to the recess for the mobile phone there is now a charging socket, to the right of that is a holder for a large bottle. The overhead controls in the communications compartment have been relocated, “anything you need to grab and see has now been moved to the front”. And the monitor for the optional 360° camera system has been moved to a new, uniform position. All the features that make life easier for drivers.

But that's not all. “We conducted a driver survey” Dietmar Denzel added. Psychologists from the University of Ulm asked drivers from several transport companies about their requests and ideas. These were then incorporated into the development. For example: City bus drivers like the familiar, round door buttons. So there are now different buttons in the new City cockpit and in the Basic and Basic City intercity cockpits. In addition, there is also a yellow light next to them to show whenever passengers have already pressed the bell.

Finally, phase 2 of the Pulse Check was started. Shortly before the start of series production, one team took a look at an early version of the bus from the regular production run. “We consider ourselves to be the first customers,” test engineer Andreas Türk explained. We check the implementation of features from phase 1. “In doing this we look into rattling or squeaking noises as well as the gap dimensions”.

In other words, manufacturing quality that plays a pivotal role at Setra. And this is particularly true for low entry buses, which as typical fleet vehicles are “under cost constraints like no other bus type”, as designer Vincent Thess stressed. “As automotive designers, we see ourselves as product developers rather than stylists.” So people like us also pay attention to the durable EDM grain of the cockpit. Making sure that the new Setra MultiClass 500 LE is en route as fresh as it was on the first day, even after many years.