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Bosch is energizing the powertrain

2015-04-04 | China | Technology News

Boost recuperation system (BRS): Bosch combines four efficient functions to create a sophisticated and innovative system: recuperation, boosting, start-stop and coasting. The heart of the BRS is the electrical machine with newly developed integrated power electronics. The BRS features a dual voltage architecture with 48 V alongside the conventional 12 V vehicle electrical system. This new system architecture enables the use of new high-power consumers which support innovative functions and energy-saving features. BRS can lower a vehicle's fuel consumption and CO2 emissions up to 15%.

Boost recuperation system (BRS)

Electric Motors SMG and IMG:Bosch provides a range of Separate Motor Generator (SMG) and Integrated Motor Generator (IMG) to cover the various applications ranging from HEV (Hybrid Electric Vehicle) of mild hybrid, strong hybrid and plug-in hybrid to EV (Electric Vehicle). The Separate Motor Generator is designed as a PSM (permanent magnet synchronous motor) with a distributed winding. Based on the design conception of high transmission ratio and rotation, it makes SMG a flexible and efficient technical solution with lesser outer diameter, lighter weight and higher range. The Integrated Motor Generator is also designed as a PSM. With a concentrated winding, it combines an extremely short length and could be easily integrated into the powertrain of various new-energy vehicles.

Electric Motors SMG

Electric Motors IMG

Power Electronic Unit: Power Electronic Unit contains inverter and DC/DC converter. The inverter which electronically controls and monitors the electric motor by power electronics ensures that the hybrid or pure electric powertrain is reliably supplied with energy from the high voltage battery. The DC/DC converter uses power from the high-voltage system to feed the low-voltage vehicle internal power supply. The Power Electronic Unit with a single inverter is specifically designed for the Chinese market as a highly cost-efficient product. The product performance is largely improved by enhanced power electronics module and the cooling system. A local engineering team is able to make quick responses to the needs of Chinese and foreign customers engaged in China.

Power Electronic Unit

Battery systems for hybrid and electric drives:Robert Bosch Battery Systems develops and manufactures high- and low-voltage battery systems on lithium-ion basis. The high-voltage battery systems for plug-in hybrids and electric vehicles are optimized for high performance and high energy density. For the 1st generation, an electric driving range of 30 to 50 km for plug-in hybrids and up to 200 km for pure electric vehicles can be realized. Bosch Battery Systems currently has seven global customer projects in series. The latest realized project – a plug-in hybrid premium business sedan - was officially launched to the Chinese market in January 2015. Robert Bosch Battery Systems is currently developing an innovative 2nd generation high-voltage battery pack which shows a significant cost down progress. In addition, the goal is to make lithium-ion batteries up to two times more powerful in terms of higher energy density and higher range. For low voltage applications, Robert Bosch Battery Systems will soon launch a compact lithium-ion 48V-battery as part of a boost recuperation system, which is a hybrid solution for reduction of fuel consumption and CO2 emissions.

Battery systems for hybrid and electric drives

Start-stop system:According to the test results of China Automotive Technology and Research Center, it shows that the start-stop system's fuel saving rate is from 7% to 27% in the typical Chinese city traffic. In terms of reliability, the entire test process does not show any damage caused by the system. What's more, starter's lifetime can reach 150,000 starting cycle proved by an endurance test. Besides, under regular driving situation, driving habit does not be changed. Standard start-stop system automatically shuts down the engine when the vehicle stops, reduce fuel consumption and emissions at idle speed. Bosch developed advanced start-stop and start-stop coasting to extend time of engine switched off for further reduction of fuel consumption and CO2 emission. With advanced start-stop, the engine will stall at low speed (<20km/h) when meet vehicle safety and the start-stop condition. With start-stop coasting, the engine will stall when releasing the accelerator pedal at higher speed up to 120km/h for further 10% additional fuel saving. Engine can synchronized restart without delay with advanced start-stop and start-stop coasting - starter engage with the flywheel when the engine speed is reducing. When driver depressed while coasting or driving downhill, the internal combustion engine will be automatically switched off. The dual-voltage supply system powers all the relevant consumers while the vehicle coasts in zero-emission, noiseless, low-resistance mode, driven solely by its momentum. As such, it conveys an entirely new driving experience.

Start-stop system

Electric Power Steering (EPS): The steering support of EPS is delivered by electric power. A sensor detects the driver's steering torque and forwards it to the electric motor via a control unit. The motor then transmits the power assistance to the steered wheels via a steering rack. Thereby, the power assistance torque is calculated and additional vehicle parameters are taken into account. Driver assistance functions in modern passenger cars are realized by a connection to the control unit of the EPS. Speed-sensitive power steering is one example of a driver assistance function that increases comfort. An example for increased road safety is the driver assistance function crosswind compensation. Crosswind or inclined road surface may produce torque on the steering wheel which can be offset by EPS. Hence, EPS is a key component realizing connected driving in modern cars.

EPS is a highly economic system due to its power-on-demand working principle. This steering system only needs energy when the steering wheel is actually turned. During straight ahead traffic situations, almost no energy is consumed. This leads to a reduced fuel consumption of 5 % (mixed driving cycle) and 10 % (city traffic) compared to a hydraulic steering system. EPS is a key component for e- mobility and highly automated driving due to its qualities regarding electrification and connectivity.

Electric Power Steering (EPS)

eScooter motor and control system: With the establishment of a joint venture in 2012, Bosch has become a relevant player in the growing wheel-hub motor segment for electrically driven scooters (eScooters) in China. Furthermore, Bosch is providing an electronic control unit that ideally supplements the electrical motor. The electronic control unit includes a boost function for maximum driving enjoyment as well as enhanced recovery of braking energy. The wheel hub motor combines high performance with a compact design. It is simply fitted in place of a conventional rear rim, which makes the installation process remarkably easy into any eScooter frame. It therefore fits to the key standards of the Chinese market. In terms of quality and performance, however, the wheel-hub motor and the electronic control unit set entirely new standards.

eScooter motor and control system

Bosch eBike systems: A new generation of bikes is taking town and country by storm and is already a part of everyday life in Europe. eBikes are a modern means of transport for modern people: people in a hurry and people who prefer to take it easy, the fit and the comfort lovers, commuters and pleasure cyclists, the sportive ones and, of course, young and old. The tailwind of technology-leading eBikes are made by components that Bosch develops to perfection and powers more than 50 leading brands in Europe. The Bosch portfolio ranges from the highly efficient drive unit (motor and gearbox) and high-quality batteries to a smart on-board and cycle computer that can be used intuitively. Perfect coordination of components holds the key to typical Bosch performance in terms of both comfort and efficiency. Since July 2014, technical and commercial experts from the newly established regional business unit in Suzhou, has now brought the tailwind of Bosch eBike systems to Asia Pacific.

Bosch eBike systems

Common Rail System CRS1-18: CRS1-18 is an evolutionary, modular Common Rail System for the Chinese market. It has a high-pressure pump developed in China, and new, cost-efficient ball-valve solenoid injectors. CRS1-18 has been specifically developed for economical passenger cars, light-duty commercial vehicles and minibuses on the Chinese market. They reduce CO2 emissions to ensure compliance with today's emission legislation (up to CN5). CRS2-20 is another Common Rail System with injection pressure up to 2000 bar which can fulfill Euro 6 emission legislation and further reduce emissions and noise. CRS2-20 is developed for passenger cars and light -duty commercial vehicles. With first debut in China, Exhaust Gas Treatment Denox5 can efficiently reduce NOx emission and fulfill EURO 6 emission legislation. It's also applied to passenger cars and light -duty commercial vehicles.

Common Rail System CRS1-18

Continuously Variable Transmission Technology and CVT Push-belts:In China, as the automotive transmission technology getting mature, the application of high efficient CVT technology has been growing significantly due to its advantages in excellent fuel economy, comfort of automated driving, and high cost-effectiveness. CVT has infinite gear ratios allowing the engine to run at its most efficient field resulting in best in class fuel economy and exhaust emissions. CVT offers continuous tractive power without disruption and therefore 100% smoothness and optimal comfort. CVT is a perfect option for city road condition. In addition, because of the flexibility of the system, CVT is an ideal match for hybrid drive trains, as it makes the integration easy and more efficient.

Continuously Variable Transmission Technology and CVT Push-belts

Turbo charging technology: with the implementation of ever stringent energy-saving and emission standards in China, downsizing engine with turbo charging technology has became one of the future trends in improving internal combustion engines. Bosch-Mahler turbo charging system consists of turbine, compressor, rotor and bearing, as well as actuator. With utilizing exhaust gas to drive the turbine wheel, it enables the engine to suck in and compress large amounts of ambient air and to consume the fuel in an efficient way, which effectively reduces fuel consumption and CO2 emission. Moreover, besides the optimized aero components on the compressor and turbine for a higher efficiency of system, the exhaust -gas turbocharger are also particularly designed to provide high engine torque even at a low speed or with limited flow of exhaust gas. The product portfolio includes seven basic variations ranging from BM60 to BM126 for diesel and gasoline engines with performance from 35 to 560 kilowatts.