Mobility Solutions

Reduced fuel consumption and emissions New Bosch technologies for commercial vehicles Hybrid technology for trucks

  • Waste heat recovery for even greater efficiency
  • Enhanced common-rail and exhaust-gas treatment systems
  • Eco-friendly CNG technology for clean commercial vehicles
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  • June 28, 2012
  • Mobility Solutions
  • Press releases

press release

In addition to enhancing already existing technologies such as common-rail injection systems and exhaust-gas treatment systems, Bosch is working on new technologies that improve commercial vehicles’ fuel economy and reduce their emissions even further. These technologies include hybrid solutions for the powertrains of medium and heavy trucks and the recovery of waste heat from the exhaust tract. “Apart from Euro VI, we are focusing on further reducing commercial vehicles’ CO2 emissions. Moreover, the additional fuel savings associated with these new technologies will mean real cost advantages for fleet operators in the future,” said Dr. Markus Heyn, president of the Diesel Systems division at Robert Bosch GmbH. And wherever an infrastructure exists for compressed natural gas as an alternative fuel, Bosch believes that monovalent and bivalent CNG systems have a promising future. This is also a question of complying with future emissions legislation in countries such as China or India, which take their lead from EU legislation. “This is why we offer injection and exhaust-gas treatment systems which are specially adapted to these growth markets,” Heyn said.

Extensive hybrid expertise from the passenger-car segment
When designing hybrid solutions for commercial-vehicle powertrains, Bosch draws on its experience in the passenger-car segment, where production vehicles already feature Bosch electric motors, power electronics, and engine management systems. The company is now transferring this expertise to components and systems for long-haul trucks weighing up to 40 metric tons and for medium and heavy delivery trucks – in other words, for trucks that benefit most from electrical powertrains. Bosch engineers are working on parallel full-hybrid technology that can be integrated into a commercial vehicle’s drive train without taking up a lot of space. When driving long distances and on multi-drop delivery runs, electrical energy can be recuperated when driving downhill or braking, and temporarily stored in a high-voltage battery. When the truck drives uphill or starts off, this energy drives an electric motor that supports the internal-combustion engine. “We calculate that this can reduce consumption by some six percent on long-distance journeys, and by as much as 20 percent on delivery runs,” Heyn says.

Recovering waste heat from the exhaust tract
A concept for converting the waste heat in the exhaust tract into electrical or mechanical energy offers a potential fuel saving of roughly five percent. Today, roughly a part of the primary energy used is lost via the exhaust as waste heat. Some of this energy can be recovered in a waste heat recovery (WHR) system, using a steam power cycle. The waste heat in the exhaust is used to generate steam, which drives an expansion machine. The mechanical energy gained as a result can be used to drive the crankshaft, either directly or via a gear unit. Alternatively, the expansion machine can drive a generator that supplies electrical energy to the on-board vehicle network or a hybrid powertrain’s traction battery. Bosch is currently developing various designs for an expansion machine, which is the main energy-conversion component.

CRSN3: enhanced common-rail system delivering 2,500 bar
In its latest CRSN3-25 version, maximum pressure in the CRSN3 injection system for medium and heavy trucks has been increased to 2,500 bar. Thanks to the optimized air-fuel mix, raw emissions are reduced. With a pressure-balanced interior, the innovative injector concept features an especially high level of hydraulic efficiency. In conjunction with exhaust-gas recirculation systems and SCR catalytic converters, Bosch high-pressure injection systems play a considerable part in reducing consumption and nitrogen oxide emissions. For example, the Denoxtronic exhaust-gas treatment system developed by Bosch allows nitrogen oxide emissions to be reduced by as much as 95 percent. Variant 6.5 of this system has been adapted to the special requirements of emerging markets. There is also Departronic, a proven system that injects a controlled amount of fuel into the exhaust tract to govern the regeneration of the particulate filter. Bosch common-rail systems, as well as Denoxtronic and Departronic, help commercial-vehicle manufacturers to comply with the US 10 and Euro VI emissions targets.

CNG as an alternative fuel for commercial vehicles
Spark-ignition and diesel engines that can also run on compressed natural gas are gaining in significance in the commercial-vehicle segment. CNG is especially eco-friendly. CNG engines emit up to 25 percent less CO2 than conventional diesel engines. Moreover, CNG is less expensive than conventional fuel. Commercial-vehicle operators thus benefit from the lower running cost of a CNG engine. Bosch supplies components and systems for three different approaches to using CNG. First, for monovalent engines. These are engines that run exclusively on CNG, and which are mainly found in urban vehicles such as buses or garbage collection vehicles. Second, for the dual-fuel engines to be found in medium and heavy trucks, where gas and diesel are burned simultaneously. When using this system, CNG can be used instead of diesel as much as 90 percent of the time. Third, for the bivalent engines used in light trucks. Their modified spark-ignition engines can be run either on CNG or gasoline. Both bivalent systems and dual-fuel engines offer greater independence in areas where the gas infrastructure is not so dense, since they can run purely on diesel or gasoline without any restriction.

  More information can be found here.

Mobility Solutions is the largest Bosch Group business sector. In 2015, its sales came to 41.7 billion euros, or 59 percent of total group sales. This makes the Bosch Group one of the leading automotive suppliers. The Mobility Solutions business sector combines the group’s expertise in three mobility domains – automation, electrification, and connectivity – and offers its customers integrated mobility solutions. Its main areas of activity are injection technology and powertrain peripherals for internal-combustion engines, diverse solutions for powertrain electrification, vehicle safety systems, driver-assistance and automated functions, technology for user-friendly infotainment as well as vehicle-to-vehicle and vehicle-to-infrastructure communication, repair-shop concepts, and technology and services for the automotive aftermarket. Bosch is synonymous with important automotive innovations, such as electronic engine management, the ESP anti-skid system, and common-rail diesel technology.

The Bosch Group is a leading global supplier of technology and services. It employs roughly 375,000 associates worldwide (as of December 31, 2015). The company generated sales of 70.6 billion euros in 2015. Its operations are divided into four business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. The Bosch Group comprises Robert Bosch GmbH and its roughly 440 subsidiaries and regional companies in some 60 countries. Including sales and service partners, Bosch’s global manufacturing and sales network covers some 150 countries. The basis for the company’s future growth is its innovative strength. Bosch employs 55,800 associates in research and development at 118 locations across the globe. The Bosch Group’s strategic objective is to deliver innovations for a connected life. Bosch improves quality of life worldwide with products and services that are innovative and spark enthusiasm. In short, Bosch creates technology that is “Invented for life.”

Further information is available online at www.bosch.com and www.bosch-press.com, http://twitter.com/BoschPresse.

PI7760 - June 28, 2012

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