Sophisticated technology for general onboard wellbeing

You are bound to feel comfortable in your vehicle if you have plenty of space – particularly if it is just where you want it. This means getting into and out of your passenger compartment easily and conveniently. Once seated, you find yourself surrounded by an airy, user-friendly, climate-controlled, soundproofed, well-lit environment with oceans of glass and controls that are easy to identify, reach and manoeuvre. These features are even more important when you spend hours and hours on board because your vehicle is your place of work. For this reason, the new Ducato boasts outstanding attributes in the field of passenger room, ergonomics, climate control and acoustic insulation. Not to mention the fact that the new model features many other new products that illustrate its comfort, for example, the sophisticated Blue&Me system, a rear TV camera and Cruise Control.

Acoustic and vibrational comfort

On-board silence is about much more than comfort. It is also an important preventive safety requirement. It promotes driver awareness and allows you to undertake long trips without getting tired. When we developed the New Ducato we therefore revised the acoustic insulation thoroughly to reduce noise transmitted from the engine and suspension and to limit vibration, wind-noise and aerodynamic wind noise.

The final result makes the model one of the quietest vehicles in its category: the articulation index is 49 when travelling at 120 km/h in fifth gear (the figure for the previous model was 44). It rises to 50 when the vehicle accelerates in third gear to 4000 rpm (compared to 45 for the previous version). The total acoustic comfort value is 74 decibels at 120 km/h in fifth gear and 75 decibels in third gear at 4000 rpm (the values for the current Ducato are 76 and 79 respectively). In particular, polyurethane foams (sound absorbent) and heat-expanding membranes were used to seal the panels and box sections to ensure insulation on the New Ducato. To damp aerial transmission, particular attention was concentrated on sealing the cab compartment from outside in order to reduce noise due to rolling and wind noise. The higher distance between cab door hinge centre lines and greater cab rigidity allowed us to achieve lower wind noise and lower noise levels while also improving door closure. The size of the flexible suspension bushes (front and rear) were also increased. Together with greater bush flexibility and higher body rigidity at the connection points, this has brought about a reduction in vibrations and noise transmitted by the road surface.

Another new feature that has allowed us to reduce weights and achieve outstanding acoustic performance was the replacement of the traditional IFF (sheet of sound-deadening material applied by hand under the body and then heat-treated by placing the vehicle in painting ovens) by the automatic application of a special spray treatment by robots. This treatment takes place in the plant paint shop and allows greater efficiency to be achieved by applying the material in the correct thickness, only where required. Development of the chassis and body was carried out by assessing engineering options in terms of acoustic sensitivity, assessed firstly using virtual procedures and then by means of experimental validation. The use of high strength steels and optimisation of geometrical shapes allowed us to achieve much higher local rigidity of vehicle and engine suspension attachment points. All this led to a minimisation of the vehicle’s acoustic sensitivity to incoming stress. The engine mounting was designed to ensure good dynamic filtering of engine vibrations, taking into account that the new power unit range requires much higher performances than the previous model in terms of power and torque.

Particular care has also been taken to combine the high handling performance, always a constant feature of excellence in Fiat light commercial vehicles, with high performance in terms of driving comfort, achieved through the targeted development of all parameters that characterise the vehicle suspension system. Although the body dimensions of wheelbase and track have been increased, excellent results have been achieved in terms of torsional and flexural rigidity. These results, together with optimisation of the elastic properties of the suspension bushes and optimisation of seat shape and padding, have allowed the achievement of outstanding comfort levels.

Climatic comfort

Temperature and humidity level inside the vehicle contribute significantly to creating ideal travelling conditions. A good climate control system must therefore always maintain these two parameters within optimum limits for the human body in all seasons (temperature between 22 and 25°C, humidity between 40 and 50%). The system fitted to the New Ducato has been tested under extreme conditions (temperatures from +40°C to -20°C) and also by means of warm up and cool down tests carried out in chambers and also by means of actual road tests carried out during the summer months in Sicily and during the winter months in Livigno and Sweden.

The major new features of the new climate control system are listed below:

• changeover from a main unit with water mixing to a unit with air mixing (this improves response speed to any minimum temperature change requested by the customer);
• the ventilation port cross-section has been increased to ensure a bigger airflow and the range and distribution of air to the windows has been improved for faster, more effective demisting;
• the adoption of an oversized condenser to increase efficiency during nose-to-tail driving with high outdoor temperatures;
• on Panorama versions, a rear climate control unit has been added for heating and cooling. In particular, distribution of air to the rear has been improved by installing channels in the ceiling panel (beneath the roof) and an outlet for each passenger (version with rear climate control) and channels under the seat in the rear foot wells (rear heated version). In detail, according to the version, a heater/ventilator or manual climate control system or an automatic single-zone climate control with radiation centre are available.

Heater/ventilator

The system offers an output of 420 m3/h for ventilation and 350 m3/h for heating. On the new vehicle, passenger compartment temperature can be raised and lowered quickly. The system operates very quietly. The window demisting function is also particularly effective. The system is adjusted by means of two user-friendly knobs that control: passenger compartment incoming air temperature and output (via a 4-speed centrifugal fan) and also flow distribution. A pollen filter is available as an option.

Manual climate control system

The New Ducato offers an optional manual climate control system with pollen filter built into the standard heating and ventilation system to guarantee an ideal temperature even when the outdoor temperature is higher than 30°C. The system is available with one or two cooling units. A single climate control system is better suited to Chassis Cab or Van versions, for example. And it is activated by means of a key located on the central console. Combi and Panorama versions (and even vans) can be optionally fitted with a supplementary air conditioner with a rear cooling unit located on the left side of the vehicle near the middle row of seats. On people transport versions and vans without a partition, cool air is distributed through a duct fitted crossways beneath the roof with 6 adjustable outlets. The side pillar incorporates a flow regulation device. Last but not least, Minibuses come with a dedicated air conditioner with ducts on the roof.

Single-zone automatic climate control system

For the first time on a Fiat light commercial vehicle, customers can order a single-zone automatic control system that manages temperature, airflow, air distribution, compressor activation and recirculation by means of an electronic control unit. The system implements an equivalent temperature climate control strategy. It records internal and external temperature by means of dedicated sensors and assesses the sensation of thermal well-being experienced by passengers, i.e. the energy exchange between human body and passenger compartment that is affected by humidity, temperature and treated air flow. A specific sensor located in a central position at the windscreen base records solar radiation on the vehicle and the angle at which the rays strike the passenger compartment. This therefore prevents the temperature inside the vehicle from rising excessively.

Supplementary heaters

The new Fiat Ducato offers two types of optional supplementary heaters to ensure an interior temperature that is comfortable even in the toughest climates. In addition to the conventional heater located beneath the driver’s seat (except for Panorama versions, where a rear heater unit is present), another two Webasto fired devices are available. The first works with the engine running and is started and managed by the electronic control unit in fully automatic manner without any action by the driver. It simply has to be below 5°C outside and for the coolant temperature to be less than 60°C. In this case, the energy is supplied to the heater by a small boiler with a diesel burner and a water pump that interfaces directly with the vehicle’s water and fuel circuits. Heat generated by the burner is transferred to the cooling circuit and then to the heat exchanger that distributes it to the passenger compartment via the ventilation system. The engine coolant is also heated simultaneously.
 
The second Webasto system is independent, i.e. able to work with the engine off. It is activated by a timer that allows both direct and programmed ignition. When it is particularly cold, the driver can set the device timer (by inputting the required ignition time) before entering the vehicle and thus enjoy the pleasure of getting into a cabin that is already warm as toast. No time need be lost scraping snow or ice off the windscreen and side windows. And there is no risk that the locks will be blocked by ice. Preheating the engine also considerably reduces the polluting substances following ignition, reduces fuel consumption and extends the life cycle of the power unit and catalytic converter particularly when the vehicle is often used over short distances. Cold starts can make diesel engines age faster than normal.

Front wheel drive and new suspension system

The New Ducato retains the same front wheel drive system (with front transverse engine) and suspension layout (MacPherson system at the front, rigid axle with leaf springs at the rear) to ensure excellent driving stability, excellent use of the load compartment and cab room, reduced weight and great versatility. Front wheel drive is also ideal for numerous conversions, particularly leisure conversions since the lack of intrusive rear transmission components means that the designers are free to design better and better vehicles from the viewpoint of passenger room. The all forward solution also makes a not insignificant contribution to passenger comfort while the agility and driving position of this architecture may be readily appreciated, particularly over motorway and mixed routes.

The suspension system, which plays a leading role in the mechanical configuration of a light commercial vehicle, is responsible for damping the transmission of wheel bumpiness generated by the different types of road surface that may be encountered in the passenger compartment, reducing body side oscillations (roll) and longitudinal oscillations (yaw), damping vertical oscillations and keeping the wheels firmly glued to the ground at all times. A good suspension means safety, comfort, lower tyre wear, full exploitation of the maximum load limits, a lower load compartment and better vehicle handling and roadholding irrespective of the surface type or operating mission. The New Ducato suspension system was designed with this aim in mind and 14,000 hours went into calculating the geometrical layout and the rebound load and attitude characteristics; 6,000 hours for calculating handling/comfort analysis; 25,000 hours for calculating the structural design of components/system; 22,000 hours of road testing and lastly, 60,000 hours of bench testing.

Front suspension

To achieve the best compromise between handling and performance in professional use (such as the increase in maximum permissible loads on the axle) the New Ducato designers developed an independent MacPherson front suspension system with certain technical improvements:
 

• new wheel struts to achieve an optimum suspension geometry;
• new design offset coil springs to increase the absorption of minor road roughness;
• triangular finned lower arm with bullhead fixed to the wheel sub-axle and anchored by flexible bushes to the chassis mechanical beam;
• mechanical beam designed to achieve the new gross vehicle weight target of 4 tonnes and secured to the body as a support for all front suspension parts (arms, steering box and anti-roll bar);
• telescopic shock absorbers secured to the body by means of flexible blocks and dust protections fitted to the shock absorbing blocks.

Rear suspension

The New Ducato rear suspension is similar in layout and architecture to the rear suspension of the previous model that displays certain major new features. Beginning with a reduction in height of the load platform and an increase in the rear track from 1740 to 1790 mm compared to the previous model.

And including versions with:

• 4000 kg gross vehicle weight;
• oversized track (up to 1980 mm for bases used by leisure vehicle bodybuilders);
• self-levelling air suspension which may be fitted to all specifications, payload and wheelbases.

The New Ducato adopts a rigid rear axle layout with leaf springs that feature shock absorbers located beneath the floor line. This means that the suspension does not intrude on the vehicle and offers greater width between wheelarches, thus resulting in a linear load compartment that can be used more effectively. The new square section tubular axle reduces bending when laden and achieves the objective of an overall gross vehicle weight of up to 4 tonnes and a maximum permissible load of 2400 kg. The shock absorbing blocks secured to the rail have been improved to withstand the force and consequent stress generated by the increased load target more effectively. The leaf spring mounting brackets have also been removed and the fastening systems have been optimised (the leaf springs are secured directly to the body), thus also reducing the weight.

So much for the new technical features. In terms of the settings adopted for flexible and damping components, the range of rear suspension systems offered by the New Ducato is very broad to meet all transport, attitude and comfort requirements. For example, Panorama versions are fitted with variable rate Comfort type leaf springs with sliding bushes to ensure outstanding driving conditions. Maxi versions may be fitted with three types of leaf spring (1 single and 2 double) according to the type of operating mission. In particular, the double leaf springs of the new van offer reduced flexibility and are particularly suitable for heavy duty use or heavy conversions on chassis cab and chassis cowl bases, while the single leaf springs are better suited for vans.

One rear suspension is available with track oversized to 1980 mm (the normal track is 1790 mm). This is mainly combined with leisure conversion bases (camper, box vehicles, mobile shops and special conversions). Due to their high centre of gravity, these applications are also fitted with a special antiroll bar as standard.

Self-levelling rear air suspension

The self-levelling air suspension deserves separate mention. This innovative feature guarantees great comfort and ensures constant attitude under all load conditions (vehicle full or empty, goods provision symmetrically or asymmetrically) and allows the rear load threshold to be reduced (up to -70 mm) to facilitate goods loading/unloading operations or to raise the vehicle at the rear to improve the ramp angle and/or passing over an obstacle beneath the vehicle. Compared to normal suspension systems, the load threshold level is lower and allows the user to lower it still further by means of buttons on the dashboard. For safety reasons, the attitude may be adjusted only with the vehicle at a standstill while the buttons are active even with the engine off. In detail, 11 positions may be selected (5 lifting, 5 lowering in addition to position 0, which corresponds to the driving level). Once adjusted, the attitude remains set to a speed of 15 km/h. Once this speed has been exceeded, the attitude is automatically restored to the nominal driving height.

Innovative equipment

Parking sensors

The New Ducato may also be equipped with a parking sensor, a device that comes on automatically when reverse is engaged (a special button turns it off). This helps with manoeuvring in tight spots or when visibility is particularly bad by notifying the driver of obstacles behind the vehicle that are outside his field of vision. Four ultrasonic sensors built into the rear bumper monitor the area behind the vehicle and send the information received to a microprocessor control unit that combines the data and detects the presence of potential obstacles. The system notifies the driver by means of an intermittent acoustic signal. Sound emission frequency is inversely proportional to distance to the obstacle (the signal is continuous below 250 mm). The New Ducato is also fitted with an external acoustic indicator to warn people in the vicinity of the vehicle when it is manoeuvring.

Rain/dusk sensor

Excellent visibility at all times is an important passive safety factor. The New Ducato may be fitted as an option with a rain and dusk sensor. This system fitted in the upper part of the windscreen behind the interior rear view mirror, first detects the presence of rain and then manages the windscreen wiper according to the amount of water present on the glass. When in dusk sensor mode, the device checks external brightness and automatically turns on the headlamps (side lights and low beams)

Reflective windscreen

This is made out of laminated glass that reflects a significant proportion of solar energy due to fine metal oxide layers deposited between the two sheets of glass. Compared to a standard windscreen, the amount of heat from the sun entering the passenger compartment is drastically reduced for an enormous improvement in thermal comfort. The uncomfortable burning sensation of sunlight on the occupants, the dashboard and the steering wheel can be reduced (thus allowing less wear on interior plastic and leather components and on the seals). Passenger comfort is increased and air conditioner use can be limited for improved on-board well-being and lower fuel consumption. The reflective windscreen is particularly effective when the vehicle is parked in the sun: it reduces the air inside the passenger compartment by up to 15°C.

Fix&go Kit

The automatic Fix&go fast tyre repair kit consists of a canister of sealant fluid, a small compressor with pressure gauge and various adaptors for inflation. The kit allows you to restore tyre pressure in the event of a puncture and continue on your journey, though you will eventually need to have the tyre repaired by a professional. The compressor may also be used only to check and top up the pressure. This kit means you do not have to carry a spare wheel and it is very useful when you want to minimise weight/bulk in the vehicle.

Variable power steering

The technical features of the New Ducato steering system are responsible for its safe, precise steering at motorway speeds, its great handling at all speeds and the limited force required on the steering wheel during parking manoeuvres and when driving around town at low speed. A state-of-the-art variable power steering system is available as standard on the 160 Multijet and as an option on the 120 and 130 Multijet. This constitutes a real first for the Light Commercial Vehicle segment. A system that makes light work of any manoeuvre, even during parking, by slashing the effort required at the wheel by almost half compared to a normal power steering system (from 5.5 Nm to 3.5 Nm in manoeuvres from a standing start with the vehicle fully laden.) It also guarantees maximum steering precision at high speeds, modulating the driver’s effort in a gradual manner.

Cruise control

The New Ducato’s list of new options includes an electronic speed governor (Cruise Control). This device allows you to drive to your chosen destination without having to press the accelerator. This makes for extra comfort, particularly on long motorway trips. The Cruise Control may only be activated above 30 km/h. The operation is carried out by means of the wheel on the left dedicated column switch. The ‘+’ and ‘-’ controls may be used to adjust the set speed. The device turns itself off automatically when you press the brake or clutch pedals or it may be controlled by a button. To return to automatic mode, simply press the ‘resume’ key on the head of the same lever.

TV camera system and rear visibility display

The system allows the driver to see what is happening behind the New Ducato. It consists of a TV camera located on the van’s rear roof beam (which incorporates the third brake light) and a display on the cab oddment shelf beneath the ceiling. The system is activated with the key inserted at a speed below 15 km/h by engaging reverse or by means of a button. It is deactivated when a speed of 18 km/h is exceeded. When reverse is deactivated, the image remains on the display for a further 5 seconds. Visibility is guaranteed at night and irrespective of the weather or vehicle conditions (even when fully laden). The TV camera guarantees a minimum coverage of 3.5 metres in length and 6 metres in maximum width.

The Blue&Me system

The New Ducato may be fitted with ‘Blue&Me’, an innovative Windows Mobile based device arising out of a joint venture between Fiat Auto and Microsoft. This changes the paradigms of in-car communication, information and entertainment to improve the comfort and quality of time spent aboard the vehicle. The easy-to-use device allows you to make/receive phone calls and listen to music while driving in a simple, safe manner. Bluetooth ® technology allows you to communicate with the outside world from the vehicle via your own personal devices such as mobile phones or hand-held computers. The product will subsequently be complemented by more advanced devices that allow you access to the numerous new products that technological progress has in store for us over the coming years: from full multimedia capability to satellite navigation. Not to mention the availability of a set of services designed to make your journeys more convenient, safe and easy.

The ‘Blue&Me’ offers a sophisticated handsfree system with voice recognition that allows customers with Bluetooth ® mobile phones to use their phones even when in their jacket pockets or handbags. This system automatically lowers the radio volume (if turned on) and allows you to hear the person you are speaking to through the stereo speakers. The system also features a high level of compatibility with mobile phones currently on the market and may be updated to new standards and to future telephones.

In detail, the ‘Blue&Me’ is fully integrated in the vehicle. The control keys are located on a panel in the centre of the dashboard to allow immediate and safe access to the system. It is also possible to find a number in your phone book by scrolling through the control panel display or mute the device for a private conversation. Among the main features, note that you store your own mobile phone on the system once only. And more: the personal phone book may be transferred fully and then updated automatically whenever the system detects the mobile phone. No voice learning stage is required due to the state-of-the-art voice recognition system. The device is also able to store up to 5 mobile phones, thus permitting more than one user in the same vehicle to make immediate use of the handsfree set; the programming may naturally be changed as and when required.

So much for the handsfree system with voice recognition; the innovative Blue&Me system offers something else: it allows you to listen to your favourite music recorded on your mobile, on the new smart phones, on an MP3 player or on a USB flash drive. This is achieved by means of a USB port in the glove compartment that allows you to connect any digital device with an analogue connection. In this way, you can play music audio files (MP3, WMA and WAV) directly through the stereo.