Mobility Solutions

Production milestone for diesel injection systems 10 million Bosch common-rail systems for commercial vehicles

  • Success of four generations of common-rail systems for commercial vehicles (CRSN)
  • Injection pressure has increased from 1,400 to 2,500 bar since 1999
  • Universal use: for commercial-vehicle, off-highway, and maritime applications
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  • February 11, 2013
  • Mobility Solutions
  • Press releases

press release

This year sees Bosch celebrating the production of the 10 millionth common-rail system for commercial vehicles (CRSN). The production figures over the past few years are testimony to the rapid development of this technology, which delivers enhanced efficiency and lower emissions: following the launch of the CRSN1 in 1999, one million systems had already been manufactured by the end of 2003. Now Bosch can celebrate another production milestone, with the 10-millionth CRSN rolling off the production line in January 2013.

Continuous development: universal CRSN model family
The first Bosch common-rail system for commercial vehicles (CRSN1) was unveiled in 1999 in the light-duty segment at Iveco (Turbo Daily). The first heavy-duty application followed shortly thereafter at Renault, and delivered an injection pressure of 1,400 bar. In 2001, the enhanced 1,600 bar system was rolled out in the U.S. pickup segment.

The CRSN3, which delivers 1,800 bar and was launched in 2005, ushered in a major advance. This system’s low-return injector delivers additional fuel savings. The design reduces the amount of fuel delivered by the high-pressure pump and, in turn, the associated drive power, increasing the efficiency both of the injection system and of the engine overall. From the CRSN3, the system evolved further with the CRSN3-20 and -22 systems in 2010. Today’s CRSN3-25 delivers 2,500 bar injection pressure. The CRSN3-25 is also available with various injection pumps to generate pressure, making it universally suited to medium- and heavy-duty commercial vehicle engines featuring anything between 4 and 16 cylinders. The injector also demonstrates its qualities in the off-highway segment, such as in tractors and construction machinery, and in the maritime segment, in yachts, cruise liners, and container ships.

The CRSN4 for heavy-duty commercial vehicles, which was launched in 2007, rounds off the extensive lineup of Bosch injection systems. Bosch has adopted the all-new, two-stage pressure generation concept for the CRSN4. In this pressure-amplified system, the fuel in the high-pressure pump is initially compressed to up to 900 bar before the injector takes it up to the maximum injection pressure of 2,100 bar. In 2012, the CRSN4 was also made available with an injection pressure of 2,500 bar. Advantages include ultrafine fuel atomization and precise multiple injections for effective, clean combustion as well as quiet engine running.

Common base: separation of pressure generation and injection
Across the generations and development stages, all CRSN systems share compelling common features, including a pressure accumulator from where the fuel is injected at high pressure into the cylinders via the connected injectors. The separation of pressure generation and injection provides additional leeway as regards engine design. Solenoid valves precisely meter the fuel and support up to seven individual injections per power cycle on the current systems. Flexible multiple injections make the engines quieter as well as reducing emissions and fuel consumption.

10 million common-rail systems for commercial vehicles and 74 million for passenger cars: paving the way to the future
Apart from injection technology, Bosch is also working on other systems to reduce fuel consumption and emissions in diesel engines. These include the Denoxtronic and Departronic exhaust-gas treatment systems, which are designed to reduce emissions of nitrogen oxide and particulates respectively. Bosch is also working on the hybridization of the commercial-vehicle powertrain.

Bosch Common Rail System CRSN3.3 for commercial vehicles: (YouTube)
Bosch Common Rail System CRS2 for off-highway operation: (YouTube)

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.”

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PI8006 - February 11, 2013

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