194000209 - INTRODUCTION - PANELS AND FRAME

CONSTRUCTION SPECIFICATIONS

Introduction

The topics are covered with particular attention to the new technical features required for passing the various tests introduced by new legislation. The descriptions and operating information provided are limited to a discussion of principles, rules and minimum precautions.For information on repair methods and vehicle specifications, see the specific sections on repair procedures.

Aerodynamics

The styling of the new car is designed to reflect great personality and originality and improves on the attributes of roominess, practicality and sturdiness achieved by previous models.The front, sides, rear and underbody were developed with particular attention to aerodynamics and allow outstanding drag coefficient values. The following values are an example:

Version with basic specification:

  • drag coefficient CX = 0.29
  • drag coefficient by area Cd x A = 0.690
These values are the result of road testing and measurements carried out in a wind tunnel.These results contribute to the noiselessness of the vehicle and significantly reduce wind noise. They also allow fuel saving.

Safety

The main aim of car manufacturers is definitely the total safety of the driver and passengers.To adapt the vehicle to highly demanding European and international market regulations, the new vehicle was designed with great attention to detail in order to achieve an optimum response in all situations.

Torsional and bending strength

Specifications

The vehicle''s great torsional and flexural rigidity ensure good properties of passive strength and also offer a number of benefits:

  • low noise due to fewer vibrations;
  • no creaking from the trim;
  • better handling by maintaining the correct suspension angles and thus an absolutely controlled drive for a sensation of stability and comfort in general;
  • greater ability to withstand breakages caused by using the vehicle over particularly uneven road surfaces;
  • sensation of vehicle compactiness;
  • to ensure long-term overall vehicle quality.

Torsional rigidity

Diagram showing deformation due to torsion
Torsional rigidity valuesBody with bonded windscreen: 9600 daNm/rad

Flexural rigidity

Diagram showing deformation due to bending
Flexural rigidity valuesBody with bonded windscreen: 870 kgm/mm

SAFETY

Preventive safety

This concerns all factors that determine comfortable driving conditions and prevent situations that could distract the driver''s attention:

  • very stiff body for greater driving safety;
  • optimised engine mountings (barycentric) to minimise vibration and noise transmission;
  • climate control system, dual zone (where fitted) with activated charcoal pollen filter with balanced diffusion throughout the passenger compartment. Well-arranged ventilation outlets allow excellent air exchange and improved transpiration and thermal comfort;
  • an extensive glazed area allows optimum visibility;
  • the tail-lights are shaped to optimise the indicator light functions;
  • the arrangement of the pedals, steering wheel (with axial adjustment and height-adjustable), main controls and warning lights has been carefully considered to achieve a good balance between driving position and ability to reach the controls;
  • the height-adjustable driver''s seat with lumbar adjustment allows the best possible driving position to be achieved;
  • generous interior dimensions allow the vehicle occupants the necessary level of comfort;
  • abundant use of sound-absorbent materials and the adoption of specific vibration-proof fasteners to reduce mechanical noise and achieve a noiseless, welcoming environment;
  • interior trim that meets the toughest flame-retardant standards.

Active safety

This concerns features of the vehicle and specific components that help the driver overcome potential dangers while driving.

The following features contribute to the vehicle''s active safety:

  • outstanding stability during driving and in terms of the vehicle''s dynamic performance;
  • excellent braking system;
  • good pick-up.

The vehicle offers features that are mutually complementary:

  • the front suspension ensures great control of the vehicle during standard or sporty driving. It allows great driving precision and vehicle control over wet and slippery surfaces, a prompt, accurate response and an ability to absorb obstacles and roughness present on the road surface;
  • multilink rear suspension with three transverse arms and one longitudinal arm designed to offer improved handling performance: the pressed steel crossmember guarantees ideal torsional rigidity for the suspension with an excellent balance between the front and rear of the vehicle;
  • smart bushes attaching the rear axle to the body for limited self-adjustment to steering modulated by the stiffness of the bushes
  • new design electrohydraulic steering system designed for a crisp, prompt response in all situations;
  • braking system big enough to guarantee powerful, safe braking without fade, consisting of two independent cross-over circuits with an ABS/EBD system (the most advanced brake control system currently available) with four channels and four active sensors to reduce activation times, equipped with an EBD (Electronic Brake Distribution) device: that does away with the need for a load proportioning valve;
  • ESP integrated traction control system with ESP/ASR/HH/HBA functions (where fitted).

Passive safety

Because in statistical terms head-on impacts account for 60% of accidents, side impacts account for 30% and the remaining 10% are accounted for by shunts, fires and rolls, the vehicle structure has been designed and developed to crumple in controlled manner in the case of impact and to absorb the energy developed without affecting the living areas of the passenger compartment.To safeguard the vehicle occupants, the seat anchorage points and seat belt attachment points (a three-part belt is also available on the central rear seat) have been reinforced.There is a protection for the occupants of the front seats with dual stage activating that includes a driver''s Air bag, pretensioners with a load limiter for the seat belts, a passenger side Air Bag (that can be manually disabled using the key in a special in the panel on the right hand side), two additional frontal impact detection sensors (driver''s side and passenger side) that assist the main electronic control unit and bringing forward the intervention of the Air Bags compared with a traditional system, reducing the risk of minor injuries as a result of the activation of the Air Bags. The vehicle is also equipped with (optional) front and rear Side Bags for the driver, the front passenger and the rear seats and head bags that extend along the roof on the left and right sides providing protection agains any side impacts to the head of the occupants of the vehicle and air bags for potecting the driver''s knees (optional).In addition, the model is equipped with ISOFIX mountings on the rear seats for transporting even the smallest passengers in safety.
If the body is repaired, the structural reinforcements should always be replaced if deformed.

Resistance to frontal impacts

General specifications

The body is made up of differential crumple zones and is fitted with reinforcements to strengthen the survival cell. These enable the car to withstand head-on impact by ensuring the passenger compartment remains intact to offer the greatest protection to its occupants and minimise the effects of impact.

The main actions taken on the body to achieve the required aims are as follows:

  • front structure with differential crumple zones designed to crumple at pre-established points to absorb and distribute the impact force over the structure due to a front sacrificial beam bolted to a crash box that can absorb even off-centre impact.
  • reinforcements on the side members and the lateral dampers connected to a box section crossmember under the windscreen that ensure transverse strengthening of the passenger compartment forming one piece with the side panels at the height of the waistline;
  • reinforcements under the floorpan that increase the solidity and stiffness of the floor to limit deformation as much as possible;
  • collapsible telescopic steering column.reinforcements on the front pillars;reinforcement on the pedal assembly.
Impact forces are further absorbed and distributed by the engine attachments that discharge the forces to the front reinforcement and prevent excessive load on the passenger compartment.These features of the structure, together with the fastening systems and the interior energy absorbing parts allow the vehicle to achieve a high level of safety and pass all the tests imposed by standards.

Composition

1 Front crossmember connecting struts2 Reinforcement on the struts3 Longitudinal reinforcements under the floor4 Reinforcements on side pillars5 Centre pillar outer element6 Centre pillar reinforcement7 Centre pillar inner element8 Reinforcements on the front pillars9 Reinforcement on the pedal assembly10 Box section crossmember under the windscreen11 Headlamp carrier front crossmember

Resistance to side impacts and roll over

General specifications

The body complies with all the most recent European standards on side impacts and rollover and is able to assure a high level of occupant safety by crumpling in a controlled fashion to prevent damage to the survival cell.

The above has been achieved by:

  • reinforcing the underdoor reails between the front pillars and the central pillars;
  • reinforcing the central and rear pillars at the rail attachment points, at the seat belt anchorage points and in the lock striker areas;
  • inserting a box section reinforcement beam between the underdoor rails.inserting a crossmember joining the centre pillars under the roof.
The doors described below contribute significantly to the vehicle''s ability to withstand side impact.

Composition

1 Underdoor rail reinforcement2 Reinforcement beam between underdoor rails (front seat support)3 Crossmember joining pillars

Structure of the doors

General specifications

The door structure is of fundamental importance to the safety of passengers in the case of side impact and the door panel geometry and stiffness is therefore designed to maintain survival spaces at the sides and minimise possible injury to passengers. The structure of the doors is supported by a frame where all the components such as the window opening device, door locks, speaker, interior door opening handle are fitted to allow the opening of the door after frontal and rear impact tests laid down by regulations.

The above has been achieved by:

  • fitting Omega type tubular side impact bars, using reinforcements at the waistline with vertical frames above the waistline and locks along the pillars to make up an ideal high-strength door ring;
  • fitting high-strength locks and strikers;
  • fitting energy-absorbing interior door trim without sharp corners designed to ensure minimum impact against the body in the event of an accident.

Composition

A: Rear doorB: Front door1 Waist reinforcements2 Pillar reinforcement3 Tubular side-impact bar4 Lock reinforcement5 Vertical frames above waist

Structure of the roof

General specifications

The specific structure of the ceiling makes the passenger compartment more rigid and contributes to passenger safety in the event of side impact or roll-over which, despite being much less likely to occur than the other types of impact, is one of the most dangerous accidents.

The following features increase the solidity of the passenger compartment structure:

  • transverse connecting box sections between the panels by the upper part of the windscreen and the tailgate;
  • lengths of structural adhesive along the edges of the upper transverse box sections for the windscreen housing and the tailgate housing which, in addition to bonding the parts with good mechanical resistance, prevent vibrations and resonance.centre connecting crossmember secured to the side pillars.
These features allow outstanding levels of strength to be achieved during the static and dynamic crushing and rollover tests required by European standards.

Composition

1 Upper windscreen box section beam2 Upper tailgate box section beam3 Roof panel4 Upper side member5 Centre crossmember connecting side pillars.

Resistance to rear impacts

General specifications

The vehicle''s resistance to rear impact is very high and passes the tests specified by the toughest standards in force in Europe.

This performance is ensured by:

  • a reinforced rear box section beam;
  • reinforcements on the attachments between the rear beam and pillars;
  • tailgate with reinforced ribbing;
  • reinforced side and rear tailgate ribbing.

Composition

1 Left rear rail2 Right rear rail3 Rail connection beam4 Rear beam5 Rear crossmember

WINDSCREEN AND WINDOWS

The fixed windows are a further safety feature.To increase the vehicle safety level, the wi
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