Mobility Solutions

Operating costs Bosch gears commercial vehicles to maximum efficiency - from injection to exhaust-gas treatment

  • Bosch reduces costs and emissions for every kilometer driven
  • 2,500 bar common-rail system with significantly reduced return flow
  • Reduced nitrogen oxide emissions even in most demanding situations
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  • September 23, 2014
  • Mobility Solutions
  • Press releases
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press release

In a systematic approach that starts with the peak pressure of 2,500 bar delivered by its common-rail system, Bosch is making commercial-vehicle powertrains energy-efficient, reducing emissions, and slashing the costs for every kilometer driven. “Our efforts to further increase efficiency start with fuel injection systems and continue on through consistently, all the way to exhaust-gas treatment,” says Dr. Markus Heyn, president of the Diesel Systems division at Bosch. At the heart of these efforts lies Bosch's integrated approach. It ensures that powertrain systems and subsystems harmonize reliably and perfectly.

Advanced Bosch powertrain solutions enable commercial-vehicle operators to lower their operating costs. Even though modern truck diesel engines already work at close to the thermodynamic optimum, Bosch's innovations enhance powertrain-system efficiency even further. The decisive factors here are developments on the micro level, such as the new CRIN3-25 injector, which prevents fuel from ending up unused in the return line. As a result, the new Bosch common-rail system can achieve fuel savings of up to one percent, shaving costs by as much as 700 euros a year. But truck operating costs also depend on the amount of AdBlue that is required to scrub oxides of nitrogen from exhaust emissions. The Bosch Denoxtronic metering system enhances efficiency by variably matching urea-solution injection to the region of the world in which the vehicle is being used. This allows vehicle manufacturers to precisely customize their powertrain design. In regions where AdBlue is expensive, Bosch can offer a systems approach that is designed to accommodate high pressures and high levels of exhaust-gas recirculation. In areas where urea is cheaper, the Bosch system aims to maximize combustion efficiency with high excess-air volumes. In this case, the combined effect of the common-rail system and Denoxtronic can produce diesel fuel savings of up to five percent.

Regardless of the configuration, SCR systems are the key to meeting demanding emission standards such as Euro 6 – and the Bosch Denoxtronic urea metering system is the essential part of this solution. As a result of the legislation that came into force in Europe in 2014, pollutant emissions from modern truck engines are around 97 percent lower than they were at the end of the 1980s. Thanks to Bosch's optimized common-rail system, CO2 emissions are also decreasing. Given the several millions of trucks that transport goods throughout Germany every day, the smallest of improvements can make a big difference. Fuel savings of just one percent per kilometer would lower annual CO2 emissions by more than 300,000 metric tons.

The following product descriptions describe in detail the improvements Bosch offers and what each technical solution is able to achieve:

CRSN3-25 common-rail system delivering 2,500 bar
Bosch's new 2,500 bar system is based on a modular systems approach. Bosch's CRSN3-25 is leak-free in both low- and high-pressure ranges. Injecting the compressed fuel that has been delivered with as little loss as possible contributes significantly to greater efficiency throughout the powertrain system. Bosch has designed a system that prevents gap leakage through which fuel can escape unused into the return line. It achieves this by subjecting the parts inside the injector, up to and including the control valve, to rail pressure. So that the nozzle needle can open at all under such conditions, the needle is hydraulically coupled to the push rod.

As well as improving efficiency, the ultra-precise, leak-free injector also ensures a cleaner fuel burn, with a corresponding reduction in particulate and other emissions. What's more, because the system pressure is retained for a long time, vehicle operators also benefit from the excellent re-start response this offers in start-stop operation.

Exhaust-gas treatment with Denoxtronic
As the amount of fuel consumed during lean operation goes down, so the nitrogen-oxide emissions of an engine typically increase. This conflict of objectives represents a major challenge for commercial-vehicle manufacturers. When it comes to making even large commercial vehicles compatible with extremely tough emissions standards such as Euro 6, the Denoxtronic urea metering system is the ideal component for the exhaust-gas system. Because it works without compressed air, it is a system that is as efficient as it is cost-effective. During development, Bosch placed particular emphasis on creating a robust design and compact configuration. Compared with the previous generation, the size of the delivery module in the latest Denoxtronic 6 was reduced by about a third. In addition, the module guarantees a high throughput of AdBlue without allowing fuel to condense on the walls. This increases efficiency. The avoidance of plastics as much as possible allows the metering module to be used for continuous operation at ambient temperatures of up to 140 degrees Celsius. This robustness gives commercial-vehicle manufacturers more freedom when integrating the component in their exhaust systems. For this purpose, Bosch Emission Systems GmbH (BESG) provides turnkey projects, assuming responsibility for the purchasing as well as for the definition and integration of all components for exhaust-gas treatment.

Bosch particulate matter sensor, Departronic, and NOx sensor
Sensors are powertrain sleuths, continuously gathering accurate, up-to-date data from the exhaust system. This data is the basis for all functions, from mixture formation to clean combustion to exhaust-gas treatment. Besides the usual sensors for determining the powertrain's exact operating mode, Bosch also offers NOx sensors for SCR-system monitoring and control, and sensors for monitoring the diesel particulate filter.

The new particle sensor from Bosch is designed specifically for commercial vehicles and for installation in the exhaust emissions box. It is highly sensitive and is therefore able to work reliably even at low exhaust-gas flow rates. In addition, the sensitivity can be increased by adjusting the tilt angle during installation. The sensor enables the reliable detection of malfunctions in the diesel particulate filter, and is compatible with both the CAN data bus and the HDSCS technology that is standard in commercial vehicles.

It goes without saying that the Bosch NOx sensor meets the high standards of reliability that apply in commercial vehicles. It is suitable for worldwide use in commercial vehicles, in both 12- as well as 24-volt systems. It can measure high NOx concentrations of up to 3,000 ppm, but features compact control electronics that are able to evaluate even very small sensor streams as well. A special coating makes it very tough, capable of withstanding extreme temperature fluctuations and the accumulation of deposits. The sensor signal retains its high measurement accuracy even when the engine has been in operation for a long period and the sensor has grown old. This guarantees the robustness of the overall system.
The particulate matter sensor works best in conjunction with Bosch Departronic. By deliberately injecting diesel into the exhaust gas, this system helps to regenerate particulate filters.

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First and foremost, the Bosch stand (Hall 17, Stand B12) at the 65th IAA Commercial Vehicles in Hannover is about efficiency. We are using smart solutions to make conventional commercial-vehicle powertrains not only cleaner, but also increasingly economical. And with technologies for alternative powertrains and fuels, Bosch has the future clearly in its sights. In addition, we show how in-vehicle and internet connectivity can help simplify logistics and make truck use even more efficient.

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 and,

PI8639 - September 23, 2014

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