· Modular system for the management of gasoline engines

In Asia’s growth markets, demand for low-cost automobiles is on the rise. For vehicles in the low-cost segment, which cost under 7000 euros, Bosch offers components and systems for both diesel and gasoline engines. Apart from helping to optimize costs in the low-price vehicle (LPV) segment, these components and systems also play a part in meeting future emissions standards in the emerging markets.

Cost-optimized and hard-wearing common-rail system.
With the CRS 1.1 common-rail system, Bosch has developed a modular concept that can be applied in the one to three-cylinder engines of both three-wheelers and mini vehicles. The system’s high-pressure pump is based on a one-cylinder plug-in pump that Bosch has long manufactured for other applications, such as construction machinery. The pump, which is designed for system pressures ranging from 250 to 1450 bar, is ideal for vehicles in the LPV segment, and this for a number of reasons, including reduced size and lower weight as well as invulnerability to differences in fuel quality. Moreover, the design of the system’s solenoid-valve injector has been simplified. Thanks to a reduced number of components, manufacturing cost is low. The CRS 1.1 common-rail system is manufactured in India.

The engine management system is based on a cost-optimized and scalable control unit platform, which can be adjusted to meet different local emissions standards. As a result, the system can comply with limits such as India's current BS 4 standard (which is equivalent to Euro 4). The control unit can be used to upgrade current generations of engines. Among other things, this will make it possible to meet future emissions standards in the emerging countries and integrate additional functions such as start-stop. The system is to be applied in a number of vehicles, such as the diesel version of the Tata Nano.

Low-cost engine management for gasoline engines
With Value Motronic, Bosch has developed a particularly cost-effective and scalable control unit platform for port-injection gasoline engines with two, three, or four cylinders. Here, too, the focus was on the low cost of components, of the electronics, and of the software architecture. Compared with standard systems, the scope of functions offered by Value Motronic is much smaller and simpler. As a result, there is less application work to do, and this also keeps costs down. The Value Motronic is manufactured in India and China. Value Motronic’s control unit platform is part of a modular system for gasoline engines in the low-cost segment. In addition to an engine management system, it also comprises sensors and actuators, such as the ZS-K 2x2 Value ignition coil. It requires only a small amount of installation space and, in the case of simple four-cylinder engines, can be expanded to include a phase recognition option, which allow the cylinders to be allocated in the control unit. This makes a phase sensor redundant. Moreover, it is possible to generate different levels of ignition energy in a single housing. This is important if four-stroke engines are to be run on different types of fuel – ranging from gasoline to ethanol and natural gas.

The DKG-PPTS sensor module is another example of a cost-effective solution. The module combines the sensors that determine the position of the throttle valves, the pressure in the intake manifold, and the temperature of the intake air. This results in additional savings with regard to cabling and assembly. The EV1-4-2 injector can be used for simple engines in regions where emission limits are currently not so strict. Here, one fuel injection valve supplies two adjacent cylinders.

Global development competencies
In developing cost-effective solutions for low-priced vehicles, Bosch benefits from its worldwide network, which encourages close cooperation between engineering sites. In China, for instance, Bosch has pooled its engineering competencies for country-specific gasoline systems components. In India, the company has done the same for LPV diesel injection components. As a result, technical solutions can be tailored to the needs of customers and specific regions.

The Bosch Group is a leading global supplier of technology and services. In the areas of automotive and industrial technology, consumer goods, and building technology, some 275,000 associates generated sales of 38.2 billion euros in fiscal 2009. The Bosch Group comprises Robert Bosch GmbH and its more than 300 subsidiaries and regional companies in over 60 countries. If its sales and service partners are included, then Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for growth. Each year, Bosch spends more than 3.5 billion euros for research and development, and applies for some 3,800 patents worldwide. With all its products and services, Bosch enhances the quality of life by providing solutions which are both innovative and beneficial. The company was set up in Stuttgart in 1886 by Robert Bosch (1861-1942) as “Workshop for Precision Mechanics and Electrical Engineering.” The special ownership structure of Robert Bosch GmbH guarantees the entrepreneurial freedom of the Bosch Group, making it possible for the company to plan over the long term and to undertake significant up-front investments in the safeguarding of its future. Ninety-two percent of the share capital of Robert Bosch GmbH is held by Robert Bosch Stiftung GmbH, a charitable foundation. The majority of voting rights are held by Robert Bosch Industrietreuhand KG, an industrial trust. The entrepreneurial ownership functions are carried out by the trust. The remaining shares are held by the Bosch family and by Robert Bosch GmbH. Additional information can be accessed at www.bosch.com.

PI6744 - August 2009