THE CONTRIBUTION FROM FIAT GROUP COMPANIES

When it produced the new Lancia Musa, 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. In detail, their contributions are as follows:

Magneti Marelli

The Lancia Musa represents the perfect combination of aesthetic elegance and exclusive engineering heritage. On the engineering side, a significant contribution has been made by Magneti Marelli that developed innovative systems and components for the new vehicle and also designed and produced the suspension layout.

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 Lancia Musa is also equipped with a D.F.N. 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 also assured by a Magneti Marelli suspension system that includes both front and rear assemblies. Lastly, the telematic system was also developed by Magneti Marelli that packed all the most advanced high-tech devices in the area of infomobility and entertainment into the latest version of the Connect system: satellite navigation system, radio, CD player with CD MP3 player, GSM phone, voice recognition, six inch active matrix colour display.

Elasis

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

Elasis was also responsible for the integration and operational checking of the torque based engine control systems and D.F.N. robotised gearbox present on the Musa. All this was achieved by using virtual simulators for 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 Lancia Team responsible for designing and manufacturing the Musa. Some of these are as follows:

• Advanced mathematical mapping and three-dimensional simulation techniques for the fluid dynamic, injection and combustion processes that underpin the operation of the Multijet that is able to achieve high power densities, low combustion noise (particularly when running at low temperatures) and above all to comply with Euro 4 emission standards ahead of time;

• 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 well-being as determined by climate and air quality; during the Nineties CRF introduced with Fiat Auto a set of projects that aim to develop an innovative climate control system that places the user at the centre of the system and can guarantee an optimum level of on-board well-being. The dual zone climate control system was also designed with these criteria in mind, to make it possible to customise the on-board microclimate in a simple and effective manner;

• 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, CRF also began developing, with Fiat Auto, the welding process that was used for the first time in the world in 2003 to complete the doors on the Fiat Idea. Now the same technology has been successfully applied also to the Lancia Musa, again using Comau's AGILASER system. The innovations that the FRC transferred to the Fiat Group for use in the Fiat Idea are protected by total of more than 50 patents (including the Multijet patents).

Comau

Comau has contributed the Agilaser system to the welding line supplied to the Fiat Group for the production of the Lancia Musa. 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. Through UTS, Comau also helped in product development both directly and by contributing to the work of codesign suppliers.