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So far, the FPT engineers have revealed all the secrets of the engine control unit as well as all the techniques used to test MultiAir engines .
But how did we reach this stage? How is a MultiAir engine born?
Here are the answers. Today’s video clip will illustrate in detail how each component is developed, analysed and assembled. The various departments collaborate with each other to ensure that the entire process flows with the maximum efficiency and precision.
Design Dept.
In the Design Dept., the engine’s behaviour is carefully analysed, both in terms of performance (power/consumption ratio) and reliability (the engine's structural resistance).
As explained by Mr Gavino, the engineer in charge of the sector, it was this thorough analysis that enabled the technical staff to significantly reduce the development time required for the MultiAir engine.
Overhaul Dept.
In the Overhaul Dept., the engines are dismantled then reassembled to ensure the highest quality and service standards, as demanded by our customers.
The cylinder head, actuator, pistons, drive shaft and camshaft are all tested in the Metrology Room to identify any signs of wear.
The parts manufactured in collaboration with suppliers are analysed and successively reshipped to suppliers for further tests.
At the end of the component analysis process, the engine is reassembled starting from the bottom (short block, crank mechanism and pistons) and sent to the test room where duration and application are then tested.
The first video clip we presented explained how MultiAir engines are assembled and tested, in terms of performance, efficiency and emissions.
Instead today’s video clip focuses on the engine’s electronic component, which is no less important.
The central engine control unit is the brain of the MultiAir . It sets the main operating parameters by defining, instant by instant, the most appropriate valve opening laws to apply.
Mr. Vetrano, the engineer responsible for engine control development, explains to us the main steps followed in the development of the electronics.
“Hardware-in-the-loop” testing made it possible to test all the engine control unit software in a virtual environment that emulates its final use on the vehicle. This system also allowed for fault injection testing, i.e. testing the engine control unit’s responses to sensor or actuator errors.
Directly on the road, using a data scanner, the engineering staff constantly monitors the operation of the main central unit strategies, measuring parameters such as the exhaust gas temperature estimator, the boost pressure model, or the parameters used to calibrate the drivability of the vehicle.
Our trip through the design, development and fine tuning of the MultiAir continues.
Today, our engineers Benfenati and Di Martino show us how the engine is calibrated and tested and which technologies are used to do this.
Engine testing rooms
In the engine testing rooms, fuel consumption, performance and emissions of the MultiAir are all tested.
The engine is placed in operation thanks to an exhaust ventilation system, a fuel intake system, an external cooling system and a lubrication system.
This makes it possible to quickly perform all the calibrations that could not be tested with the same precision directly on the vehicle.
Roller bench
This test represents the final testing bench where all the strategies of the engine control unit are checked to ensure they are free from flaws.
Individual components, engineered by the Design Unit, are tested directly on the vehicle to ensure they can support the stress of on-road driving.
Fulfillment of fuel efficiency targets is checked directly on the road. Alfa Romeo MiTo must comply with Euro 5 legislation.
Anechoic chamber
This special area is used to test the acoustic comfort inside the vehicle.
The engine must not transmit vibrations or other unwanted noise.
Mr. Martorelli, the engineer responsible for the FPT Unit, explains that this has been one of Alfa Romeo’s distinguishing features for many years.
We expect Alfa Romeo MiTo MultiAir to live up to our expectations yet again.
Today is no ordinary day; with this video clip filmed in Pomigliano d'Arco a few days ago, the MiTo Team adds the final piece to the video-mosaic dedicated to the MultiAir technology.
All the information and know-how we have tried to convey up to now will be very useful; all the video clips will remain at your disposal on the blog and YouTube channel, so study them carefully!
Here’s some good advice for now: your patience will be amply rewarded!
Now let’s talk about the video clip. This time, the AlfaMiToBlog team travelled to Campania to meet the people who produced the first MultiAir engine model.
In this video clip you will see the faces and hear the words of the people who produced every single part of the engine, who assembled and tested it with the utmost precision.
We admit to feeling somewhat moved in visiting the FPT plant in Pomigliano, a place which oozes passion for cars at every corner and where technical expertise reaches the highest levels.
Take our word for it!
Carbon Dioxide (CO2) is one of the most harmful gases for the environment.
Its dispersion in the atmosphere causes a series of effects, first of all the greenhouse effect.
MultiAir was not only created to optimise engine efficiency, but also to reduce consumption of combustion gases that produce CO2 and other hazardous gases.
In the third episode of the MultiAir saga, Mr. Andrea Ferrari, the engineer in charge of the "Testing Facilities" of FPT explains how MultiAir impacts consumption and consequently, the polluting emissions produced by the car.
MiTo was mounted on a roller bench connected to a computerised system capable of simulating the car’s resistance to forward motion.
MiTo’s exhaust pipe was then connected to a device that mixes exhaust gases and ambient air and then feeds them through a series of instruments that analyse and accurately measure the polluting compounds emitted by the engine.
Both naturally-aspirated engines and supercharged engines with the same displacement recorded around a 10% reduction in consumption levels.
Engines that implement the so-called “downsizing” technology recorded a further reduction in consumption levels. This system allows for constructing engines of reduced dimensions and weight that retain the same performance levels of naturally-aspirated engines. In this case, the values were around 20-25%.
While we await the publication of the other two episodes on the MultiAir engine, our Team will try answering the
many requests for clarification that emerged last week.
Please consult the following table which summarizes the technical features of the
MiTo 1.4 TB 135 HP.
Emissions, consumption, performance and much more: get a more in-depth view.
What are you waiting for? Tell us what you think!
Alfa Romeo MiTo 1.4 TB 135 HP - Technical features
cylinders, alignment
4
Bore x stroke (mm)
72x84
Displacement (cm3)
1368
Compression ratio
9,8:1
Maximum power kW (hp - EC) at rpm (NORMAL)
99 (135) 5000
Max. power kW (hp - EC) at rpm (SPORT)
99 (135) 5250
Max. torque Nm (kgm - EC) at rpm (NORMAL)
180 (18,3) 1750
Maximum torque Nm (kgm - EC) at rpm (SPORT)
206 (21) 1750
Timing system (control)
Toothed belt with hydraulic tappets and Mair system on aspiration side
Fuel delivery
Supercharged through exhaust-driven turbo-compressor with variable valve actuation for managing engine load
Injection system
Electronic, phased sequential injection with detonation control and variable valve actuation
Stop&Start device
Stop&Start system for automatically shutting down/restarting the engine in the event of short idle phases during the urban cycle. This system optimises consumption and CO2 emissions.
Battery: capacity(Ah) / Generator (A)
63Ah/450
Traction
Front
Gears
5 + R
Final drive ratio
3,733
Basic commercial type
195/55 R16
Steering box
Rack and pinion assembly with electric servo-drive on column
Curb to curb turning diameter (m)
11,25
Front
Mc Pherson
Rear
Torsion bar
Front (mm)
281
Rear (mm)
251
Fuel tank capacity (litres)
45
Weight in running order DIN (kg)
1135
Max. towable weight (kg)
500
Max. speed (km/h)
207
Acceleration (1 person + 30 kg) 0-100 km/h (s)
8,4
Consumption (l/100 km) - urban driving cycle
7,4
Extra-urban driving cycle
4,5
Combined driving cycle
5,6
CO2 emissions (g/km)
129
Servicing
30,000 km
Energy class
Euro 5
Acceleration in 1st gear from 60 to 100 km/h
- 5% VS T-jet
Acceleration in top gear from 80 to 120 km/h
- 6% VS T-jet
Welcome to part two of the MultiAir propulsion system where we explain how the new system works.
Today’s video features Massimo Fulfaro, one of FPT’s (Fiat Powertrain Technologies) development engineers. He’ll be showing you all the technical details using an example engine.
Yet another opportunity to learn all about this incredibly innovative technology which has been under development since the early 90s and is destined to fit under the bonnet of the Alfa Romeo MiTo for many years to come.
How it works
Getting get down to the technical details of the MultiAir engine, the key to this system is its intake valves.
A piston driven by a mechanical intake cam is connected to the intake valve through a hydraulic chamber, which is controlled by a normally open on/off solenoid valve.
When the solenoid valve is closed, the oil in the hydraulic chamber acts as a solid body and transmits to the intake valves the lift schedule imposed by the mechanical intake cam.
When the solenoid valve is open, the hydraulic chamber and the intake valves are de-coupled; the intake valves no longer follow the intake cam and close under the valve spring action.
The final part of the valve closing stroke is controlled by a dedicated hydraulic brake, to ensure soft, regular landing in any engine operating conditions.
This controlled solenoid valve opening and closing system makes it possible to obtain a wide range of different optimum opening schedules for the intake valves.
At full load
The solenoid opens near the end of the cam profile, causing early intake valve closing, thus maximising the mass of air trapped in the cylinders.
At part-load
The solenoid valve is opened earlier, controlling the air mass in proportion to the required torque.
Alternatively, the intake valves can be partially opened by closing the solenoid valve once the mechanical cam action has already started. In this case the air stream into the cylinder is faster and results in higher in-cylinder turbulence. The last two actuation modes can be combined in the same intake stroke, generating a so-called “Multilift” mode, that enhances turbulence and combustion rate at very low loads and RPM speeds.
Advantage
The time has come at last, all ye MiTo-maniacs. True - we made you wait for it: but we on the Team know how great your trust and patience are.
And you won’t be disappointed, because we worked every second of that time to offer you absolutely unique materials.
In line with the blog’s tradition we have recorded the experience of the designers and makers of Alfa Romeo MiTo’s new engine: the MultiAir!
Nothing less than a revolution in the field of petrol engines, comparable to common rail technology for diesel.
During the month of July, AlfaMiToBlog will post a mini-series, a storehouse of news and curiosities that will satisfy even the most demanding readers!
Today's star guest is one of the leading engineers of Fiat Powertrain Technology:
Engineer Damiano Micelli, Head of Petrol Engine Research.
Enjoy the video!
Dear MiTomaniacs, the moment has finally come. Without hesitation, omission, delay or uncertainty:
Listen carefully and hear the echo approaching on the breeze of a hot summer’s day.
Wondering what it could be? The answer lies in just one word we’ve been waiting to shout out for some time: MultiAir!
The new engine designed and built by FPT, Fiat Powertrain Technologies, is finally ready for release on the market. The first “open door” is scheduled for September, but we can already reveal the first vehicle to benefit from this jewel: the Alfa Romeo MiTo!
The sportiest compact ever has been chosen as the MultiAir project 'pilot' vehicle and only further attests to our great expectations in its potential.
This truly revolutionary technology in the field of engines is the result of years of study and experimentation. The journey has been long and hard with plenty of difficulties along the way, but the result is a truly great technical success.
AlfaMiToBlog will tell its readers the exclusive story behind what MultiAir really means through 4 videos created in collaboration with FPT and Alfa Romeo. Four chapters to illustrate the history, technology and production of this new jewel of Italian motoring.
See you on Wednesday, the 1st of June, for the first episode. Don’t miss it!
As you all know, just a few days ago Alfa Romeo MiTo GTA was awarded the "Auto Europa Tuner 2009” prize. The prize was presented to Fabrizio Corigliano, Alfa Romeo Marketing Manager Italy, during My Special Car in Rimini.
Even greater satisfaction considering that the MiTo GTA triumph was decreed by both UIGA journalists (28.26 % of preferences) and the public (32.14 %).
This convergence of experts and simple fans combines positions that are not always in line with each other; this is not a foregone result. A competent opinion guarantees a margin of high level “objectivity”; but public opinion proves that, also from an “emotional” point of view, MiTo GTA has conquered Alfista hearts.
The new Alfa Romeo 159 versions are on their way to all European dealers; here’s the calendar
BELGIUM - 30 March
ITALY - 4 April (doors open weekend 4-5 April)
GERMANY, FRANCE, SWITZERLAND, SPAIN, GREECE – mid April
OTHER EU MARKETS – beginning of May
These are two engineering jewels worth special attention considering their high technological content.
1750 Turbo Petrol 200 HP
This power unit carries on the great Alfa Romeo 1750 cc tradition. 3000 cc performance in a small sized and consumption engine. Here are the solutions behind that result.
“Scavenging” technology
Slow running torque maximisation and really fast response to the driver. Angle and valve crossing times are defined more precisely generating a flow of air from the intake collector directly to the exhaust and fast turbo-compressor drive. The result is surprising: pull-in torque at 1500 revs increased 70% compared to a traditional turbo.
Turbo
The new turbo-compressor is linked to an innovative “Pulse Converter” type exhaust collector: that’s the secret to increase the slow running torque. Both collector and turbine are in precision cast stainless steel for really high operating temperatures (max 1020 °C) very important to reduce consumption at medium/high speeds.
Performance
Pull-in torque (320 Nm) reached at 1400 revs is a point of absolute excellence. This guarantees excellent performance without having to use gears too often. And then the high specific 115 HP/l power is reached at the relatively low speed of 4750 revs/min, staying constant till 5500 revs/min.
Emissions
Thanks to double injection and “high pressure start”, emission value is Euro 5 with a relatively small catalyser (positive effects on performance).
2.0 JTDM 170 HP
Natural evolution of the 1.9 JTDM which, though increasing torque and power, comes under euro 5.
Drive with minimum pre-heating times thanks to a new type of “low voltage” plugs.
From 82 mm to 83 mm: increased bore, plus a new variable geometry turbo, puts this engine at the top of the market.
All this and reduced consumption: for example, in the combined cycle the Alfa 159 saloon records 5.4 litri/100 km. Then the compression ratio has dropped from 17.5:1 to 16.5:1 (consistent drop in NOx).
Respect of Euro 5 emission limits is guaranteed by use of a close-coupled DPF (CCDPF) and an advanced exhaust gas recirculation system (EGR), in which all sub-components are grouped into a single, small sized element (EGR module).
Reality has come true! The Alfa MiTo GTA Concept will be starring at the Geneva International Motor Show.
A golden opportunity for all the Ambassadors and readers of this Blog!
The “Gran Turismo Alleggerito” is written on the very heart of Alfa Romeo, and the legend continues with this new, and much longed-for model, the MiTo GTA Concept. The MiTo will have the honour of continuing a line that has produced very special cars like the
Giulia GTA, which continues to stand out as an icon of style, like a lighthouse at sea.
Just three key words suffice to capture the secret of the MiTo GTA Concept: balance, weight and power.
Engine
The propulsion has been specifically designed to drive MiTo GTA Concept. 1750 Turbo Benzina, 240 CV – a name and surname of some significance behind which lies a top-performance engine. At the standard consumption rate of a 4-cylinder engine, this new design attains performance levels worthy of a 3000cc worthy of a 3000cc!
The unit features direct injection, twin-phase continuous variators, tubo-charging and a revolutionary management system. A combination of avangarde solutions for a powerful yet easy-to-manage engine all rendered possible by the Alfa DNA system.
Body of the Car
There are some very significant changes here. This is mainly because Alfa Romeo has managed to reduce the weight without any negative effects on the performance of the suspension which depends on the excellent drag-torque control. The final touch is the complete revision of the structural reinforcements which has led to a reduction of mass and an impressive lowering of the centre of gravity. The benefits to the steering are tangible: greater agility and an excellent grip on the road.
Materials
The most interesting novelty is the use made of aluminium and carbon-fibre. Aluminium is used in the brake system, for the suspension and for some parts of the chassis. Carbon-fibre is used instead to reduce the weight of various parts such as the rear spoiler, the roof and the mirror caps.
Interior
The interior design is just out there waiting to be discovered and is entirely in keeping with the GTA philosopy.
Once you have settled into the sculpted front seats and buckled the four-point seat-belts attached to the rear roll bar, you will be awed by the black opaque anti-reflection dashboard. The lining, including the front, central and rear pillars, is completely upholstered in black Alcantara and embellished by a stitching that runs all around the inside of the car. The MiTo GTA also comes provided with new, specially designed air vents, an ergonomic steering wheel, gearstick knob and brushed aluminium pedals Alfa 8c- style. And, last but not least, the speedometer records up to 300 Km/h .
Radionav
The system was designed together with Magneti Marelli. It enables one to control the functioning of the vehicle such as the engine oil temperature, the turbo-charger and the aperture of the throttle. And of course, there is a system to monitor acceleration and braking power thus providing much invaluable information on your personal driving techniques.
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