3239247 - Introduction - PANELS AND FRAME
SPECIFICATIONS:
INTRODUCTION
Aerodynamics
The style of the new car, featuring smooth lines which are modern yet, at the same time, recall styles of the past, contains all of the sporting tradition of Alfa Romeo plus the quality of a large saloon. - The aims of adaptability, comfort, functionality and strength already achieved on previous models have all been consolidated.The front section, the sides with flush windows and joined surfaces, the rear section and underbody have been designed with particular attention to the aerodynamics aspect which, together with the typical lines of the make, permits an excellent aerodynamic coefficient (CX = 0.315) and aerodynamic coefficient per area (CX x S = 0.639). These values are the result of measurements made in the Fiat wind tunnel.SAFETY
The main aim of car manufacturers is undoubtedly the complete safety of the driver and passengers.The regulations on both the European and the world market have become very demanding in this respect, and to meet this requirement, the new Alfa Romeo car has been designed in order to respond in the best possible way to all situations.Preventative safety
This involves all those factors which determine comfort and allow situations which could distract the attention of the driver to be prevented:
- extremely rigid bodyshell;
- optimum engine mountings;
- climate balanced throughout the interior compartment, with anti-pollen filter and diffusers which permit an excellent air exchange and better transpiration and thermal comfort;
- controls and warning lights illuminated, so immediately legible;
- addition of the third stop light in advance of the regulations (1 September '98).
Active safety
This involves all the features which contribute actively to driving safety:
- dual crossover independent circuit braking system with ABS, fitted as standard on all models, with electronic distribution of the braking force (EDB) with active sensors which reduce the actuation times;
- 'high quadrilateral' front suspension, similar to those used in racing, ensure a high degree of control with both sporty and normal driving style. The advantages of this suspension are felt in: the driving precision and controlability of the vehicle, even in the wet and in poor grip conditions, an immediate and precise response and a capacity to absorb obstacles and uneven road conditions;
- McPherson rear suspension with new geometry with a self-aligning effect, which enables the vehicle to be stabilized during steering, facilitating control even in extreme manoeuvres, and optimizes roll and pitching reactions;
- steering and power steering designed to allow a precise, immediate response in all situations.
Passive safety
The structure of the Alfa 156 is designed to crumple in controlled fashion in the case of impact from the front, side or rear and to absorb impact energy without affecting passenger compartment living space.Main features of the passive safety system
On both the basic version with driver's Air Bag, fitted as standard on all versions, and on the version with driver's and passenger's Air Bag, the car car has been successfully tested in accordance with the following methods:
- offset frontal impacts, test (AMUS/ADAC and ECE R94) and at high speed (USA 208), the front crumple zone and the strengthened passenger compartment cell with reinforcements at key points, ensure excellent performance;
- dynamic side impacts, the structure of the side panel, centre pillar and reinforced door panels ensure conformity to future retgulations (ECE R95);
- Roll-Over (standard (USA 216), the structure of the roof and high resistance pillars ensure the survival cell;
- prevention of the intrusion of the load transported in the luggage compartment: ensured by the partition behind the backrest and the links to the bodyshell;
- resistance to rear impacts, standard (ECE 32/34 - ECE 17/04), ensured by the reinforced structure and the new rear side members;
- impacts at low speed (4 - 15 kph), special design features have made it possible to minimize damage;
- front and rear bumpers which pass the test mentioned in the standard (ECE 42) without damage.
Fire safety
This is achieved through the FPS (Fire Prevention System) which consists of:
- internal fire extinguishers which restrict the propagation speed of the flames (standard USA 302);
- inertia switch for cutting off the fuel pump;
- a reflux valve and antimisfiring shields (overheating of the catalyzer on petrol versions);
- a system protecting the cables through which high intensity currents flow;
- no fuel leaks and retention of the battery in the case of an impact or overturning, standard (ECE 34);
- fuel tank made from a plastic material which has high mechanical and fire resistant properties, located in front of the rear axle and firmly secured to the bodyshell via three bands;
- steel tubes in the spark out area.
Torsional and flexural rigidity
The high flexural and torsional rigidity of the Alfa 156 body, in addition to ensuring high passive strength, transmits a sensation of solidity and comfort in general, maintaining correct suspension angles and offering absolute driving precision. In effect if the bodyshell, with windscreen and rear window and without moving parts, is subjected to a torsional force (A) of 1780 kgm, it only yields by one degree.
These impressive strength figures lead to many advantages:
- lower vibrations;
- lower noise;
- improved driveability;
- – increased resistance to failure caused by the use of the vehicle over particularly uneven roads;
- – the sensation of a compact car;
- – improved maintenance in time of the overall qualities of the vehicle.
Resistance to frontal impacts
 | In the case of operations to the bodyshell, if the structural reinforcements are distorted they must always be replaced. |
Resistance to side impacts and roll-over
In the case of side impacts or roll-over, the bodyshell crumples in a controlled manner in such a way as not to compromise the survival cell, thus protecting the occupants.The above has been obtained by reinforcing the central pillars in several places, along the entire length, at the seat belt anchor points, at the door lock striker areas, using a crumpling cross-element under the seat joining the central floor and front frame to optimize the distribution of forces, and a multi-layer central hoop connecting the central pillars on the sides under the high-strength roof.A further essential element in the resistance to side impacts consists of the doors which are discussed in the paragraph which follows.
Structure of the doors
The structure of the doors is of fundamental importance for the safety of the passengers in the case of side impacts and has therefore been designed with optimum geometry and rigidity of the door panels to keep possible injury of the occupants to a minimum. The structure of the doors allows them to be opened after the most severe frontal impacts (AMUS) and rear impacts (ECE 32). This has been achieved by adopting anti-intrusion tubular bars, waist reinforcements and by inserting foam material between the panels.
Structure of the roof
The particular structure of the roof, apart from outlining the profile of the car, gives greater rigidity to the unit, contributing to the safety of passengers in the case of both roll-over and side impact. In the structure, illustrated in the figure below, the hoop joining the central pillars of the side panels is secured by screws. In addition, to increase the solidity of the structure, structural adhesive is applied along the edges of the hoops in contact with the roof, which, apart from glueing the parts with high mechanical strength, acts as a sealant and prevents leaks between the box sections and the roof, thus preventing the occurrence of rust.
Resistance to rear impacts
The resistance to rear impacts exceeds the tests mentioned in the regulations (ECE 32/34, ECE 17/04) and is assured by the longitudinal members and the crossmembers, the rear box section coating, the crossmember under the rear window and the shelf under the parcel shelf, the bulkhead behind the squab, which also protects against the movement of the load transported in the luggage compartment at the time of the crash, and against the rear floor on which there is an anti cave-in crossmember which helps retain the rear seat occupants.A further reinforced area is the door frame which allows the doors to be opened as mentioned in the regulations (ECE 32).SALOON
Interior compartment and seats
To protect the occupants in the event of a crash, inside the interior compartment the dashboard has been designed with rounded profiles and made of a foamed crumple material, with particular attention to the area under the steering column to minimize possible injury to the driver's legs; in addition, to protect the upper body, apart from the Air Bag which is fitted as standard for the driver, there is also a high energy absorption magnesium steering wheel.The furnishings are completed by covers in a high energy absorption material featuring rounded profiles and surfaces with seats which have been made extremely comfortable through the use of differentiated carrying capacity foams and upholstery padding to ensure optimum support for the various parts of the body. For the driver's seat, the combination of height adjustment and height and axial (depth) adjustment of the steering wheel, standard on all versions, allows the driver's place to be optimized for all drivers.
The following measures have been adopted to contribute to the safety of the driver and the passenger in the front seats:
- seat belts: height adjustable with a double mounting on the seat, with an electronically controlled pretensioner and high efficiency reel which keep the belt in the correct position irrespective of how the seat has been adjusted, where the outside seat belt mounting has been moved from the centre pillar to the seat (detail A) and the seat belt attachment to the seat, tunnel side (detail B) has been shortened to reduce the possibility of lengthening of the belt. This solution, in addition to the added benefit for the seat belt wearer, also improves the retaining of the occupant compared with traditional systems, with the belt mounting on the floor, allowing a considerable reduction (up to 30%) in acceleration and allowing the body to be kept in the correct position contributing to the anti-submarining effect;
- magnesium alloy structures, with reinforced squabs and cushion bottoms with anti-submaring effect profile, with high containment and high energy absorption properties;
- bilateral micrometric squab adjustment which permits better positioning of the squab and eliminates the possibility of 'falling backwards' in the case of adjustment during driving;
- height adjustment up to + 40 mm in relation to the standard position, which can be set by means of a ratchet lever with extremely small loads which is easy to use, sliding longitudinally on sloping guides so that the forward movement of the seat is also accompanied by the raising of the seat.
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