New fully variable hydraulic valve control
system cuts CO2 emissions by up to 25 per cent

A collaborative development between the Schaeffler Group and Fiat Powertrain has resulted in a groundbreaking new engine system, the world's first fully variable hydraulic valve control system.

A groundbreaking system for automotive power transmission systems has been launched, which reduces vehicle fuel consumption and cuts CO2 emissions by up to 25 per cent.

UniAir, a joint development between the Schaeffler Group and Fiat Powertrain, is a unique fully variable hydraulic valve control system that will make its debut on Fiat's new Alfa MiTo 1.4 MultiAir. This is the first vehicle within the Fiat Group to be equipped with this innovative technology.

As well as offering car manufacturers a more compact valve control system, UniAir will help the automotive industry meet future CO2 emissions targets for passenger cars. UniAir provides improvements in start-up, part load and acceleration behaviour of the vehicle. During the engine warm-up phase, for example, hydrocarbon (HC) emissions are up to 40 per cent less, and nitrogen oxide (NOx) is reduced by up to 60 per cent. In addition, UniAir offers a greatly improved driving experience through more power, higher engine torques and optimised engine response.

A groundbreaking system for automotive power transmission systems reduces vehicle fuel consumption and cuts CO2 emissions by up to 25 per cent.

Car manufacturers will be particularly impressed by the fact that UniAir enables car engines to be downsized. Fiat uses UniAir in its four-cylinder FIRE series of engines and in its small volume two-cylinder engines that are currently being developed. As well as petrol engines, UniAir will also be available for diesel engine applications.

Developed for series production by Schaeffler, UniAir refers to the system as MultiAir. This name follows the style of the MultiJet CommonRail direct diesel injection system, which was also initiated by Fiat. UniAir/MultiAir is also based on an invention by the Centro Ricerche Fiat (CRF). The takeover of the license in 2001 marked the beginning of successful development collaboration between Fiat and Schaeffler, culminating in series production and market launch. In 2003, the first functioning prototype was developed. Further prototype vehicles were manufactured two years later.

The final design specification was completed in 2007 and manufacturing facilities for series production started at various Schaeffler Group locations in 2008. MultiAir has been in development for Fiat and Alfa Romeo since May 2009.

"The development of the fully variable valve control system to production standard has involved complex efforts in the fields of mechanics, hydraulics and valve control software," explains Michael Haas, Director Advanced Engineering and Business Development at Schaeffler Group Automotive's Engine Systems unit. A 45-strong development team undertook these tasks.

How it works
UniAir is a cam-actuated, electro-hydraulic valve train system. The fully variable valve control can be used for both petrol and diesel engines and is supplied via the existing engine oil circulation system. For petrol engines, UniAir enables throttle-free, continuously variable, software-based load control across the entire engine map. With diesel engines, regulation of the temperature of the combustion chamber is achieved due to the precise control of exhaust gas recirculation rates. At the same time, the effective compression ratio in the cylinder can be varied and a homogeneous combustion ensured.

For the first time, UniAir allows not only variations in the valve stroke, but also in the opening and closing of valves several times during one cycle, at different points in time. Therefore, the system significantly expands the potential of traditional valve train mechanisms.

UniAir can provide full coverage of every conceivable airflow possibility, from zero lift to maximum lift, dictated by the camshaft lobe for each individual cylinder or valve. With the de-throttling of the engine, UniAir can provide early intake-valve closing or late intake-valve opening in order to maximise engine breathing relative to certain engine speed and load conditions. UniAir offers unique valve lift events for every valve - individually and cycle-to-cycle. In contrast, an electromechanically actuated, fully variable valve train requires several cam events to achieve the same lift differential.

"UniAir is the beginning of a new era in valve trains and therefore in technology, producing engines that are eco-friendly and dynamic at the same time," commented Dr Peter Pleus, Executive Vice President of Schaeffler Group Automotive.

For further information on Schaeffler's range of automotive engine components, view website: www.schaeffler.co.uk   Refer to next page

Cooperation between Bozzio, DSM, Bern University and
Dynamic Test Centre brings safer mobility for people with disability

The joysteer® X-by-wire system with precision gears made of Stanyl® PA 46 resin from DSM Engineering Plastics is now in commercial production for the handicapped market and available from car modification companies in Switzerland, Germany and the Benelux. This rapid development from prototype to successful commercialisation was achieved by the Swiss company Bozzio within record time of just three years. In this period, Bozzio obtained the strictest level of safety approvals for the European market (TÜV approval according to ECE-R 13H braking system and ECE-R 79 steering system), making joysteer®x-by-wire commercially available to provide people with a disability a user-friendly solution to drive a car with safety and confidence. This is the first system with such a high safety level.

Matthias Hell, Bozzio CEO, explains "We are proud to have brought to commercial production this important advance for people with a handicap offering them greater mobility. Our patented joysteer® X-by-wire system is the end result of intensive cooperation by material supplier DSM Engineering Plastics, Bern University for Applied Sciences, Dynamic Test Center (crash test) and many others."

Refer to pictures above: The gears sets made from Stanyl polyamide 46 (PA46) resin in joysteer® X-by-wire system translate the driver's steering movements into vehicle control.

Bozzio now foresees a host of potential applications for their patented X-by-wire system in special-purpose vehicles, such as municipal and agricultural vehicles, unmanned vehicles, areas requiring a high degree of reliability and safety. As Hans Wennekes DSM, Business Development Manager Stanyl, states "This patented technology made available by Bozzio opens new opportunities for Stanyl polyamide 46 (PA46) resin in wide scope of special purpose vehicles." 

The joysteer® system
The gears sets made from Stanyl polyamide 46 (PA46) resin in joysteer® X-by-wire system translate the driver's steering movements into vehicle control. Two joysticks are mounted and coupled electronically to the vehicles steering mechanism. The driver's movement of the joysticks is computed by joysteer® and the data sent to the control module that turns the steering column and thus steers the car. The Stanyl gears are part of the steering actuator module. Stanyl polyamide 46 (PA46) resin fulfils the essential requirements for dimensional stability, low wear and the ability to absorb vibration and noise. Stanyl polyamide 46 (PA46) resin has an extra strong crystalline structure which makes it highly suitable for demanding automotive and electronic applications. To get an impression of the system's capabilities, view  website: www.joysteer.ch/uploads/media/joysteer_OnTheRoad.wmv to see the movie.

DSM Global Gear team in profile
As well as supplying the resin for the gear system, DSM Global Gear team supported the development of joysteer® X-by-wire system with technical expertise in gear train design, in-depth tribology, materials development, processing and market insights. In addition, DSM together with forteq-group teamed up the total supply chain which enabled functional gear train prototypes to be produced in the shortest possible time. DSM's global gear team which was set up to offer value-added services in application and business development to support gear application operates in Europe, USA and the Asia/Pacific region.

For further information, e-mail: sandra.coolen@dsm.com  Refer to next page 

Bozzio AG in profile
The X-by-drive system was initiated by the Swiss organisation for people with disabilities (ASRIM) and developed by Bern University of Applied Sciences. In 2006, the spin-off company Bozzio was set up to take up the process of obtaining TÜV approvals and to commercialise the system. Working with recognised automotive suppliers, Bozzio is supplying mechatronic components to car modification companies. In close cooperation with two car modifiers in the Netherlands and Switzerland, Bozzio has conducted all driver tests with disabled people. In 2009, final homologation was achieved and the first cars are now on the road. The target volume in Europe is 300 systems in 2012.

For further information, view website: www.bozzio.ch