You will find the figures mentioned in this article in the German issue of ATZ 05I2007 beginning on page 378.

Der neue Smart Fortwo

The New Smart Fortwo

Authors:Klaus Badenhausen, Markus Bibinger and Ralf Peter

After a life span of eight years which has seen more than 770,000 vehicles roll off the production line, Smart is now launching the second generation of the now iconic Fortwo. The new vehicle continues the distinctive concept em-bodied by this ultra-compact two-seater. A whole host of original solutions deserve a closer look – from the plastics technology which features in the body panelling and the panoramic roof to the automated transmission and the economical engines.

ATZ 05I2007 Volume 1092

1 Introduction

The new Smart Fortwo has been on the market as a Coupé and Cabrio version since April 2007. The scope of variants includes a choice of three petrol engines rated at 45 kW and 52 kW (naturally aspirated) and 62 kW (turbocharged), plus a turbocharged 33 kW direct-injection diesel engine. Similarly to its predecessor, the new Smart Fortwo (series A/C 451) is once again the epitome of a compact two-seater predestined for urban use. Smart has maintained the established concept while developing the vehicle sub-stantially in accordance with changes in the law and customers’ expectations. The Smart Fortwo retains its characteristic fea-tures, despite considerable optimisation measures in the area of design and con-struction.

2 Vehicle Concept and Design Features

The new Smart Fortwo retains the vehicle layout with rear wheel drive, which has proven the only satisfactory solution for a vehicle length which now stands at 2,695 mm. Concept studies showed that the dy-namic changes of axle load have a particu-larly critical effect on braking when such a short vehicle is fitted with a front-mounted engine.

Statutory requirements on the protec-tion of pedestrians in Europe and crash performance stipulations in the USA have necessitated marginal growth in x direc-tion to the tune of 195 mm in comparison to the predecessor model. Requirements in the areas of driving dynamics and passive safety clearly indicated a need to position the drive train at the rear axle. This is the only way of reconciling parameters such as directional stability, minimal dynamic changes of axle load and satisfactory crash performance.

Table 1 and Table 2 show dimensions and weights of the new Smart Fortwo.

In just eight years, the Smart Fortwo has become firmly established as an inte-gral part of the motoring world. It has ac-quired the character of an icon for the Smart brand – its concept and design re-main unique to this day. It has also won broad social acceptance, as demonstrated by its inclusion in the collection of the Museum of Modern Art in New York, for example. In order to meet the needs and expectations pertaining to the status which the car has achieved, the onus has been on retaining defining elements and developing these with due sensitivity.

2.1 Exterior DesignThe following terms of reference apply with regard to the stylistic elements for the exterior: One-box architecture, large wheels, minimalist overhangs, headlamps positioned over the front grille, round rear lights. The steel body shell which is partially visible as the vehicle’s outer skin combines with plastic panelling to define a contrasting two-colour design as a char-acteristic stylistic element. This contrast-ing design also emphasizes the employed combination of materials.

A pronounced shoulder line lends the body of the car a longer appearance. In contrast, the design of the wings empha-sizes the horizontal lines, investing the body structure with width and ensuring that the vehicle sits firmly on its wheels.

2.2 Interior DesignThe interior of a Smart Fortwo traditionally imparts a feeling of space, despite the com-pact nature of the actual dimensions. Clear-ly structured functional elements empha-size the vehicle’s modular design. The exten-sive use of textile elements on instrument panel and door trims bring the two-materi-al/two-colour concept to life inside the vehi-cle. Integral seats featuring sporty contours and positioned in a staggered arrangement exude a solid, robust character which em-phasizes the importance that has been at-tached to the passive safety concept.

The newly designed instrument panel retains the signature Smart division into two levels while now sporting straight lines as opposed to the previous sweeping S form, Figure 1. Controls, displays and indicators are bundled according to functions – the air conditioning control unit is positioned on the top level of the centre console, for exam-ple, while the instrument cluster, air vents and dashboard instruments are located on the instrument panel.

3 Engines

Totally new, compact three-cylinder en-gines with a capacity of 999 ccm lend the new Smart Fortwo performance capabili-ties far beyond those of its predecessor. There is a choice of three naturally aspirat-ed engines, rated at 45 kW and 52 kW and a turbocharged variant generating 62 kW of power. Plus a 33 kW cdi. As on the pred-ecessor, the engines are mounted transver-sally in front of the rear axle, inclined at an angle of 45 degrees towards the rear and interlocked with an automated five-speed manual transmission (AMT).

3.1 Petrol Engines Both engine variants, Figure 2, feature a weight-conscious all-aluminium design, from the oil pan to the cylinder head cover. The cylinder barrels take the form of grey cast iron liners. Gas exchange is controlled by four valves per cylinder. The variable valve timing system (VVT) provides for opti-mum spreading of the intake and outlet cams for every engine speed by electro hy-draulic means. The corresponding maps are defined in the Bosch ME 7 engine con-troller. The long-stroke design contributes to a favourable torque characteristic – and to a small block length, with a cylinder spacing of 80 mm.

Fuel metering is carried out by an elec-tronic injection system, which converts the commands, that the driver inputs via the accelerator pedal, into acceleration by means of an electronic accelerator. A non-return fuel delivery system with a pressure-controlled low-pressure pump (delivery module) in a plastic tank supplies fuel to the fuel distributor rail of the injectors. The engine, which is supercharged at a maxi-mum of 0.5 bar, possesses a sensor which supplies information on the pressure situa-tion upstream of the turbo, thus enabling more exact control of the induction mani-fold pressure. The exhaust system is at-tached to the body shell in such a manner as to isolate it from vibration, rather than being fitted to the engine as on the prede-cessor. The compact muffler system also bears the catalytic converter, as previously.

3.2 Diesel EngineWith a capacity of 799 ccm, the three-cylin-der diesel engine, Figure 3, in the Smart Fortwo is the smallest direct-injection en-gine in the world. It has undergone a thor-ough revamp for deployment in the com-pact two-seater, resulting in ten per cent more power (33 kW at 3,800 rpm) and a corresponding rise in the maximum torque (110 Nm ranging from 2,000 to 2,500 rpm). Its high-tech credentials include a light-al-loy design for the cylinder block and cylin-der head and state-of-the-art injection tech-nology. The common rail injection system operates at maximum pressures of 1,600 bar. It now employs new seven-hole injec-tors to allow even finer atomisation of the fuel than previously.

In order to minimise the already low level of particle emissions, the engine is equipped with a diesel particle filter (open system) as standard (in D, A, CH). The Smart Fortwo cdi emits 0.013 g of particles per km; this value will fall considerably from 2008, when the closed system becomes

ATZ 05I2007 Volume 109 3

COVER STORYSmart Fortwo

available. The particle reduction system is accommodated together with an oxidising catalytic converter and the muffler in a sin-gle stainless steel housing. The exhaust gas which is returned to the combustion proc-ess (as inert gas) is cooled in order to reduce nitrogen oxide emissions (NOx).

3.3 Fuel Consumption Despite a ten per cent boost in power out-put and a slight increase in the weight and size of the car, the fuel consumption of the Fortwo cdi according to the new European driving cycle has been limited to 3.3 l per 100 km. This corresponds to a CO2 emission level of 88 g/km. This low consumption in combination with the 33 l capacity of the new fuel tank results in a range of around 1.000 kilometres – an advantage which is also attributable in part to systematic weight optimisation throughout the entire vehicle. The petrol engines are also well be-low the 130 g CO2/km which will be re-quired by the EU as of 2012, at 112 g CO2/ km for the 45 kW and 52 kW versions and 116 g CO2/km for the 62 kW turbo. The Smart fleet averages 108 g CO2/km.

Table 3 gives a survey of engines, driving performance and fuel consumption.

4 Transmission

Smart customers benefit from a newly de-veloped automated manual five-speed transmission (AMT) based on the corre-sponding transmission in the Smart For-four. The clutch is opened and closed by an electric motor. Five gears have proven ideal in view of high-torque engines and a top speed (electronically limited) of 145 km/h (cdi: 135 km/h), whereby gear and axle ra-tios have been adapted to the different en-gine characteristics.

An advanced concept has enabled the interruptions in tractive power during gear-changing to be shortened considerably in comparison to the predecessor’s trans-mission. The time between the beginning of the clutch opening process and the end of the clutch closing procedure has been more than halved. This reduction applies to an even greater extent when shifting down by two gears.

The AMT of the Smart Fortwo is able to execute gear-changing commands so quick-ly because two gear selector drums which are driven by two electric motors move the shift forks and sliding sleeves, Figure 4. One unit is responsible for second and fourth gears and reverse gear, while the other is allocated to first, third and fifth gears. Four

shift forks move the shift sleeves together with the synchronising hubs. Delays are eliminated by moving the shift sleeves to the synchronisation points in preparation for the gear shift. Table 4 shows the trans-mission data.

5 Chassis

The driving dynamics of the new Smart Fortwo offer a further increase in agility coupled with noticeably more comfort in comparison to the predecessor model. The 2007 Fortwo translates steering commands very spontaneously into changes of direc-tion. This is attributable to the shorter total steering ratio in mechanical and power-as-sisted variants, as well as wider tyres, changed vehicle dimensions, optimised axle kinematics and chassis tuning.

The steering angles required on the steer-ing wheel have been reduced considerably, wider tyres on the front axle translate the wheel angle more directly into the turn radi-us desired by the driver. The body is support-ed against rolling by an 18.5 mm thick anti-roll bar on the front axle, which in the inter-ests of more sensitive response is now hinged to the damper strut rather than the wish-bone, and by supporting springs positioned further to the rear and to the outside on the rear axle. This has made it possible to omit the rear anti-roll bar. Figure 5 shows the front and the rear axle of the new Smart Fortwo.

The fact that the roll centre on the rear axle has been raised by 60 mm as a result of repositioning of the central mount has had a positive effect on the agility of the Fortwo. This repositioning has resulted in more ef-fective dive and squat compensation. At the same time, the slightly more steeply in-clined roll axis increases yaw damping by 12 per cent, leading to a subsequent improve-ment in directional stability and road adhe-sion. The yaw damping results from the phase lag of the jaw response. The splitting of the lateral forces into roll and yaw in the interests of a reduced roll component addi-tionally enables more comfortable chassis tuning without compromising driving dy-namics. Longer strut arms result in reduced toe-in changes.

The new Smart Fortwo’s rack-and-pinion steering with direct transmission can also be produced in an electric power-assisted configuration. The steering ratio of the new-ly developed rack mechanism stands at 21:1 (predecessor 24:1) for the power-assisted variant and 22:1 for the mechanical steering option. The steering wheel travel from stop to stop is 3.5 turns. The boost power varies

according to vehicle speed, steering angle and the amount of force applied to the steer-ing wheel. It provides for a gentle linear rise in the force needed to control the steering wheel over the entire steering angle.

6 Safety

The moderate increase in length to the tune of 195 mm has no effect on this vehi-cle’s legendary ability to manoeuvre into the tightest of parking spaces and actually leads to a substantial improvement in safe-ty. Activities in this area have focused on the protection of pedestrians (EU) and the requirements pertaining to approval for the US market.

The front end has been increased in length by 72 mm on the European and US variants alike. In the interests of pedestrian protection, the front spoiler has been pro-vided with 50 mm thick foam backing at impact height, Figure 6. For the same reason, the axes of the windscreen wipers are con-cealed and detachable. The rear of the vehi-cle has been lengthened by 68 mm, with the entire added length serving as a deforma-tion zone. All interior trims have been opti-mised to prevent injuries to occupants.

6.2 Robust and Corrosion-resistant Steel BodyThe new Smart Fortwo features an opti-mised tridion safety cell. The body shell in conventional steel design has been enlarged slightly, together with the vehicle as a whole. In keeping with the specified require-ment for the vehicle to be street-legal in the United States too, the body shell conforms to the US crash regulations (FMVSS 208), in addition to meeting the relevant European requirements. Despite the increase in size, the body of the Fortwo Coupé is only slightly heavier, while the Fortwo Cabrio has main-tained the same weight as its predecessor. The safety cell of the Coupé now weighs in at 158.5 kg, including paintwork, while the Cabrio’s cell weighs 168.5 kg. Both contain over 50 per cent high-strength sheet metal.

The body shell of the Fortwo Cabrio shares 70 percent of its sheet metal parts with the Coupé. The body shell continues to consist of a comparatively small number of components: 114 for the Fortwo Coupé and 134 for the Fortwo Cabrio.

6.2 Restraint SystemsThe front airbags come in full-size format – 130 litres for the passenger and 70 litres for the driver. The airbag on the passenger side is now positioned at the top of the instru-

COVER STORY

ATZ 05I2007 Volume 1094

Smart Fortwo

ment panel. This repositioning has been car-ried out to minimise risks relating to activa-tion of the airbag when the passenger is not in the intended seated position or is not wearing a seat belt, as investigated in the test in accordance with FMVSS 208. The side airbags (optional in EU, standard in USA) cover the chest and head area (head-thorax airbags). Pyrotechnic belt tensioners keep the occupants in sync with the vehicle’s pulse and provide for controlled forward movement by means of belt-force limiters.

6.3 SeatsThe seats in the Smart Fortwo feature close-fitting, anatomically correct shaping, inte-grated head rests, good lateral support and above all an exceptionally robust design. This is of crucial importance, as the seats form a key element of the passive safety concept. Apart from the seats themselves, another typically Smart feature is their po-sitioning within the vehicle, with the pas-senger positioned 125 mm further back than the driver. This offers freedom of movement for driver and passenger while at the same time helping to prevent them from colliding with one another in the event of a side-impact. The adjusting mech-anism allows the backrests of both seats to be folded down with the greatest of ease. The high mechanical stability of the seats stems from a foam-filled metal shell in the seat area and an extremely rigid sheet-met-al and tube structure for the backrests. The side airbags are fitted in the backrests.

On the fabric-covered seats (knitted fab-ric), a roughly five millimetre thick breath-able spacer fabric such as is also used in sports textiles is incorporated as an inset in the backrest area.

6.4 Doors and Flaps The doors and flaps of the new Smart Fort-wo embody the brand’s hallmark design principles: A bearing structure made of metal (doors) or plastic (bottom part of tail-gate) is clad on the inside and outside with bodypanels. In the interests of a further im-provement in crash performance and with due regard to the special requirements per-taining to approval for the US market, the door structures of the new Smart Fortwo are made of steel, as opposed to the alu-minium structures which have been used to date, Cover Figure. The doors for the Coupé and Cabrio are largely identical. Panels and profiles made of high-strength steel are used at strategically important points. Examples here include the diagonal braces or the door channel strips. The rear lids on the Fortwo Coupé and the Cabrio

are now identical: A glass fibre-reinforced polypropylene structure bears the CBS pan-el on the outside, while on the inside the lid is designed as a storage compartment for the two roof side bars.

7 Interior

7.1 Cockpit The driver and passenger in the new Smart Fortwo are presented with an instrument panel featuring a straight-lined design, rather than the classic sweeping S form. In the interests of passive safety, the under-sides of the instrument panel are rein-forced with energy-absorbing knee pads in front of the driver and passenger. Positive crash characteristics are also one reason for producing the cockpit with a flax/PP com-posite structure.

7.2 Heating and Air Conditioning Temperature-controlled air conditioning is available as an option for all Smart Fortwo models. The corresponding control unit is positioned at the very top of the centre con-sole, where the control unit for heating and ventilation is located for the basic equip-ment variant. The control unit enables the air flow to be distributed to the newly de-signed vents in such a manner as to ensure draught-free air conditioning (heating). Op-timised air ducts in a totally new design also help to improve the system’s efficiency. To-gether with the new components – compres-sor, evaporator, condenser, intake pipe and heater – these enhancements result in an air conditioning system which is 20 per cent more powerful than its predecessor.

8 Body

8.1 Bodypanels in PPTo date, the bodypanels of the Smart Fort-wo have been produced in polycarbonate (PC). This plastic was blended with poly-butylene terephthalate (PBT) to render it resistant to cracking. The Smart developers have now replaced this material with poly-propylene (PP), Figure 7. PP offers the advan-tages of a lower specific weight and greater resistance to chemical influences. As a re-sult of reduced material thicknesses, total weight savings of 15 per cent have been achieved. The material’s chemical inert-ness meant that the painting processes had to be adapted, however. In order to open up the surface, it now undergoes flame treat-ment prior to applying the paint. Black, white and yellow panels can be produced

with moulded-in colour. PP marks a nota-ble advance on the environmental front: Its manufacture is kinder on the environment than that for PC. Widespread standard processes are available for recycling PP. And 30 per cent recyclate can be incorporated into components such as wheelhouse lin-ers, underbodies, etc.

8.2 Roof ConceptsSmart is currently producing three model variants of the Fortwo with a single body shell variant. The corresponding roof mod-ules are bonded to the body shell. A black or transparent (panoramic roof) roof mod-ule in polycarbonate is available. Using plastic instead of glass enables a substan-tial reduction in weight, which gives rise to various benefits including a positive effect on the vehicle’s centre of gravity. A fully automatic Cabrio top is available as an ad-ditional alternative.

8.2.1 Fully Automatic Folding Cabrio Soft TopThe soft top of the new Smart Fortwo Cabrio comes with a number of important additional features in comparison to its predecessor. An automatic function now enables the rear top to be opened to its end position and docked up with the C-pillar when closing at the touch of a button. This optimisation of the system allows the soft top to be opened and closed while travel-ling at any speed. The soft top now also fea-tures a heated rear window made of single-layer safety glass, Figure 8. As on the previ-ous Smart soft top systems, the soft top is transported in the area up to the C-pillar by means of a cable and central drive motor.

A further touch of a button is all it takes to lower the rear part of the soft top: The two electric motors responsible for this movement are connected directly to the folding top linkage by means of a pinion and gear segment. A self-locking worm drive for the gearwheel provides the appro-priate transmission ratio for the movement of the folding mechanism and guarantees that the mechanism is stopped on reach-ing its end position.

When depositing the soft top in its end position, a metal linkage folds the rear win-dow into a virtually horizontal position. In view of the large size of the window, in or-der to enable the soft top to be folded in the desired manner the glass has to be slid out of the top of the fabric. The soft top itself is produced in a black polyacrylic fabric on the outside with a polyester/cotton mix on the inside. A rubber layer joins the two of them. The system weight of the complete soft top module stands at 30 kg.

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COVER STORYSmart Fortwo

8.2.2 Panoramic Roof Made of Polycarbonate The panoramic roof made of polycarbonate plastic covers an area of 1.1 m2, including a transparent area of 0.53 m2. As is customary on the Smart, the roof module is bonded to the tridion safety cell. State-of-the-art plastics technology enables this break-resistant material to be used extensively in vehicle manufacturing. The material has a scratch-resistant exterior and interior coating which also gives the roof a dark tint that corresponds to Venus 10 for glass. The material is impervious to ultraviolet light. Those wishing to shut out the sunshine can close the interior sunblind, which consists of a non-trans-parent polyester fabric and covers the entire transparent area of the panoramic roof. The panoramic roof is produced in a two-component injection moulding process, whereby the sec-ond component serves to blacken the rim area. At 9.2 kg in-cluding sunblind, the polycarbonate module is two kilograms lighter than the conventional glass roof.

9 Electronics and Comfort Functions

Back when the first Smart Fortwo was launched, data bus sys-tems to network the on-board control units were an avant-garde technical feature. In 2007 they are very much state-of-the-art. In the new Smart Fortwo the network of data bus systems to con-trol complex functions has undergone systematic expansion. A CAN bus enables the engine and transmission software to com-municate with the electronic stability programme, the air con-ditioning controller and other control units, for example. LIN systems network comfort features inside the vehicle.

The scope of available functions in this area is unusually broad for this class of vehicle: Rain/light sensor including “driveway illumination” function to activate the driving lights, a radio option with six-disc in-dashboard CD changer, switch box to control the audio rendition of mobile telephone, naviga-tion system and iPod through the hifi system, Bluetooth hands-free system, electric windows with tap function for opening and closing and much more besides.

Engine, transmission and clutch functions are now con-trolled via a torque interface. The torque on the crankshaft serves as the control variable here; it is calculated very reliably from the ignition timing angle, fuel injection quantity, air masses and engine speed and enables the desired torque to be supplied very quickly as well as providing for faster and more user-friendly gearshifting and clutching processes. Shifting comfort has been enhanced substantially by rendering the considerably shortened interruptions in tractive power almost imperceptibly gentle.

10 Summary

The new model range of the Smart Fortwo is showing a great number of improvements, which allow for customer´s demands as well as emphasizing the strength of the vehicle concept. With quite a number of technical innovations aboard, the car meets all legal standards and is well prepared for the future. Especially against the background of the actual CO2 debate, this is gaining more and more importance: The avarage fleet emission of all smart vehicles of about 108 g CO2 per kilometer is proving the fortwo´s relevant contribution to protecting the environment and to the avarage fleet emission of DaimlerChrysler.

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COVER STORY

ATZ 05I2007 Volume 1096

Smart Fortwo