A car capable of a genuine leap forward in the compact MPV category. This was the brief given to Fiat's engineers and technicians at the beginning of the Idea project. To achieve its goal, Fiat deployed its best resources and ensured that maximum quality and reliability standards were applied throughout the product development and construction process.

It also developed a profitable co-operative relationship with its outside suppliers and some Group Companies including Magneti Marelli, Elasis, Fiat Research Centre and Comau. All our hard work generated the many smart ideas and innovative solutions that the Fiat Idea is now introducing to its segment.


Magneti Marelli

Like the Punto, Panda and Lancia Ypsilon before it, the Fiat Idea features a technological contribution from Magneti Marelli. The company developed innovative systems and components for the new car and designed and produced the suspension configuration.

More specifically, for the diesel engine control system, Magneti Marelli produced the heart of the 1.3 16v Multijet (electronic control unit software and hardware) that is already fitted to recent Fiat and Lancia models. The diesel engine control system, and also the petrol system to some extent, features a cutting edge exhaust system, again developed by Magneti Marelli, that includes catalytic converter, silencer and piping.

The Fiat Idea is also equipped with a 'Dualogic' gearbox control system with sequential and automatic functions. This is a development of the fast, reliable F1-derived Selespeed robotised gearbox - the cream of Magneti Marelli's output. The highest levels of comfort and safety are assured by a Magneti Marelli suspension system that includes both front and rear assemblies. The exterior design of the Fiat Idea also benefited from innovative support from the company. Engineers from the Automotive Lighting division designed the big front light clusters that help convey a sense of reassuring solidity with their smooth, seamless shape.


Elasis

The Control, Vehicle and Power Unit System Divisions of Fiat's Southern Italian research company contributed to the creation of the Fiat Idea by developing the new 1.4 16 valve Fire power unit that is particularly notable for its performance and fuel consumption.

Elasis is responsible for the integration and operational verification of numerous control systems on the Fiat Idea: including the torque based engine, Dualogic robotised gearbox (with new automatic mode features), ESP system and parking sensors. All this was achieved by using virtual simulators for the entire car (Virtual Car) and individual engine and gearbox subsystems (Hardware in the Loop) and by developing specific algorithms (e.g. fuel level recognition) through rapid prototyping methods.

Not to mention the fact that the new model underwent various tough tests to examine electromagnetic stress (to an intensity 25 times the maximum level specified by Italian law). The tests were conducted in the Elasis Centre's EMC (electromagnetic compatibility) laboratory, a large, screened anechoic chamber (23 x 11 x 9 metres) that is one of the most advanced of its kind in Europe. The same record can be claimed by the elastokinematic rig (K&C) at the Pomigliano d'Arco Centre that was used for instrumental tests performed on the Fiat Idea suspension system in conjunction with Magneti Marelli.


Fiat Research Centre

Innovative procedures are required to build a revolutionary engine like the 1.3 16v Multijet, or any successful vehicle for that matter. These allow customer requirements to be interpreted to achieve outstanding comfort and performance, low fuel consumption and emissions under all service conditions and also top safety, quality and dependability.

The FRC therefore developed new procedures and transferred them to the Fiat Team responsible for designing and manufacturing the Fiat Idea. Some of these are as follows:

• Advanced mathematical modelling and three-dimensional simulation techniques applied to the fluid flow dynamics, injection and combustion processes that underpin the operation of the Multijet engine;
• Design procedures for structural parts of the engine that permit reliability, but also outstanding comfort in terms of acoustics and vibrations;
• Quality Indices (QI), that allow the vehicle's technical features to be correlated to customer perceptions so that the car can be tailored to its customers in accordance with corporate brand values;
• Setting-deployment-achieving targets, that take customer targets and translate them into technical design targets for the various vehicle systems: engine, suspension, body, interiors etc;
• Multidisciplinary structural optimisation, used to optimise the design to create efficient structures that offer maximum performance and minimum weight;
• Crash and biomechanical procedures, that afford the passenger compartment cell the best possible occupant protection and ensure the car front end is compatible with vulnerable subjects (pedestrians, cyclists etc.) in compliance with current and future legislation;
• Computerised fluid flow dynamics, that allow car aerodynamics to be optimised for improved fuel economy and wind noise while also ensuring the best possible design in terms of internal comfort and wellbeing as determined by climate and air quality;
• NVH (Noise-Vibration-Harshness) methods, aimed at minimising noise and vibration to ensure a comfortable, noiseless passenger compartment under all driving conditions to reduce stress and benefit the driver's health and alertness;
• Car dynamic processes (handling), a traditional trait of Fiat, Lancia and Alfa cars, allowing a satisfying, predictable drive under all speed, manoeuvring and grip conditions via careful design of the suspension and controls (steering and brakes);
• Physical and cognitive ergonomics, backed by virtual reality for more effective design of spaces, interior systems (seats, facia etc.), main and secondary controls, moving parts and communication interfaces to ensure that driver-vehicle interaction is considered at the design stage.

At the end of the Nineties, the FRC set up an ambitious international remote laser welding cooperation project in conjunction with Comau. In 2001, the first prototype system was installed at the FRC and the Centre then used this as a basis for further development. The final outcome was the Comau 'Agilaser' application for completion of mobile parts on the new Fiat Idea model.

The innovations that the FRC transferred to the Fiat Group for use in the Fiat Idea are protected by a total of more than 50 patents (including the Multijet patents).

Comau

Comau offers the first glimpse of its 'Agilaser' system in the welding lines supplied to Fiat for production of the new compact MPV. This innovative approach to remote laser welding is arousing increasing interest in the sector. This new technology, patented by Comau, allows innovative product design solutions for improved productivity, flexibility, use of space and process costs.

More specifically, the 'Agilaser' is the heart of two technological islands where the doors are welded. The system works using two mirrors that guide a laser beam with great speed, allowing it to weld at an angle of up to 240° to beam direction. The 'Agilaser' also guarantees a consistent workload because it is part of a gate handling system with a high level of reliability, accuracy and repeatability.

Comau considers that the applications to which the 'Agilaser' is currently best suited are the welding of doors, floors, frames, sides and subunits in general, but the potential applications of this new technological approach to remote laser welding are bound to widen.