Automotive technology

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  • August 21, 2014
  • Press kit
  • Automotive technology
  • Presseinformations: 2

Powerful, and perfect for limited installation space The new Bosch HEF109-L starter motor for commercial vehicles Extended power range for exceptionally large engines

  • Powerful solution for diesel engines of up to 28 liters displacement as well as for stationary gas-powered engines
  • Engineered for mileage of up to 800,000 kilometers or 14,000 operating hours in off-highway applications
  • Adaptable to stringent system requirements
Large-volume engines place great demands on starters. At the top end of the power range, Bosch has a new addition to its 24-volt starter motor portfolio: the HEF109-L “large” heavy-duty starter motor for commercial vehicles and off-highway applications. The powerful starter motor generates 18 percent more power than the tried and tested “M” (medium) type starter motor on which it is based, and thus delivers a maximum output of 9.2 kilowatts. This is enough to reliably start engines with up to 28 liters displacement. Ulrich Kirschner, the president of Bosch’s Starter Motors and Generators division, sums up the benefits as follows: “This new high-performance starter motor is an excellent choice for particularly large engines such as construction machinery. These engines were previously very difficult to start with single starter-motor configurations.” This powerful single-starter solution makes a more complex parallel-starter system unnecessary. The technology is designed to achieve a mileage of up to 800,000 kilometers in on-highway use or 14,000 operating hours in off-highway applications.

Compact, robust, and reliable
The design of the HEF109-L with its 6-pole excitation concept is especially compact, making it particularly suitable for applications where installation space in the engine compartment is limited. The high thermal robustness ensures reliable starting of large engines – even at very low ambient temperatures or in long-lasting starting sequences.

Due to the significantly greater service-life requirements associated with commercial vehicles, the engagement itself is designed as a two-stage process in order to limit the wear of the ring gear and pinion: In the first stage, the pinion shaft including the pinion is moved forward cautiously, engaged, and turned slightly. In the second stage, the main current is released and the actual starting sequence takes place.

A mechanical relay integrated in the starter makes a connection to the engine control unit (ECU) easier. Unlike starts by ignition switch, the ECU can automatically control the starting sequence, which keeps emissions low.

For extreme conditions
The HEF109-L can also be upgraded. One example is the special dust protection, available up to IP57 protection class. An additional feature is the isolation of terminal 31. This separate connection to the battery’s minus pole is a feature of special applications such as railroad vehicles or watercraft, where increased safety and protection requirements against moisture and water apply. For maximum flexibility in diverse installation conditions, the starter motor can also be supplied with all common flange geometries, including a rotatable flange.

Parallel starter-motor systems with increased power output
For applications utilizing even larger-displacement engines, Bosch offers parallel starting systems. By setting two or three starter motors of the 109-family in a parallel-system configuration, the output of each individual starter motor can be aggregated. The new HEF109-L also allows the total output of the parallel starter-motor systems to be increased significantly. With a maximum output of almost 28 kilowatts, diesel engines with displacements of up to 84 liters and gas powered engines with displacements of up to 168 liters can be started reliably under normal conditions. Engines of this size are very common in off-highway applications and watercraft. Stationary engines such as generator sets – also need to start quickly and reliably to stabilize the power supply net if there is a power cut. The HEF109-L is an ideal choice for these applications as well.
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  • August 21, 2014
  • Press releases
  • Automotive technology
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Customizing exhaust-gas treatment Bosch Emission Systems: market for clean truck and construction machinery powertrains booming

  • Manufacturing in Neunkirchen expanded
  • “Market for off-highway segment and commercial vehicles will double by 2020,” says Dr. Markus Heyn
  • Growth of diesel in the United States boosts business
Ambitious emissions standards are boosting business worldwide for Bosch Emission Systems GmbH & Co. KG (BESG). Regulations such as Tier 4 final emission limits and Euro 6 are driving demand for exhaust-gas treatment systems for trucks, diggers, and other mobile machinery. “When it comes to commercial vehicles, the global market for these systems will double by 2020,” predicts Dr. Markus Heyn, president of the Diesel Systems division at Bosch. To keep pace with this rapidly increasing demand, BESG is now bringing new production facilities online in Neunkirchen, in Germany’s Saarland. At 3,500 square meters, the existing production halls reached the limit of their capacity some time ago. Now, nearly 15,000 square meters are ready for use. “In our new plant, we can make sure our manufacturing and logistics processes are ideal and cost-effective from day one,” says Uwe Becker, technical plant manager in Neunkirchen.

This expansion of facilities in Germany is only one of the ways Bosch can benefit from the forecasted market upturn. In addition, Bosch engineers are constantly refining the product portfolio, which covers everything from integration to the manufacture of complete exhaust systems – for both on- and off-highway applications. What’s more, BESG in North America has also started equipping large passenger cars, such as SUVs, with complete exhaust-gas systems. One of the drivers of this is growth in the diesel market in North America, with models such as the Jeep Cherokee or Dodgeb Ram 1500 serving as landmark projects. Currently, 37 diesel models are available in the United States; by 2017, that number is expected to jump to 60.

Bosch’s innovative integrated systems lower emissions per driven kilometer for passenger cars, commercial vehicles, and construction machinery. BESG can individually configure all systems to customer wishes and integrate them into vehicles or machinery, including certification. In addition, Bosch Emission Systems specialists provide systems for stationary applications such as generators.

Bend, weld, and laser
Three state-of-the-art manufacturing technologies are at the heart of BESG’s production operations. First, a fully electronic machine bends pipes measuring 2.5 to 6 inches in diameter; thanks to special tools developed in house, even the tightest bending radii are possible. Second, the latest robotic welding technology ensures efficient synchronous welding of components. Third, Bosch Emission Systems can cut complex shapes in all three dimensions using a globally unique laser system.

The company
Bosch Emission Systems GmbH & Co. KG was founded in 2010 as a joint venture with two other partners. Since then, BESG has been developing, manufacturing, and integrating exhaust-gas treatment systems for construction machinery and commercial vehicles. Bosch assumed sole ownership of the company in October 2012. Altogether, BESG currently employs more than 200 associates at its Stuttgart, Cologne, and Neunkirchen locations. At the Kentwood plant in Michigan, Bosch Emission Systems USA (BESU) also manufactures products for the U.S. market. Bosch Emission Systems is a reliable partner to automakers and engine manufacturers worldwide. This applies in particular to turnkey projects, in which BESG is responsible for purchasing as well as defining and integrating components.
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  • August 06, 2014
  • Press releases
  • Automotive technology
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ABS and MSC protect against accidents Bosch safety technology for motorcyclists Offers the best possible brake and acceleration support – now also in bends

  • Bosch offers safety technology for all classes of motorcycle
  • ABS can prevent a quarter of all motorcycle accidents resulting in death or injury
  • MSC motorcycle stability control can help in two thirds of the motorcycle accidents occurring in bends due to rider error
  • Multi-year statistics show that sunny weather leads to a rise in the number of motorcycle deaths
Motorcycling is becoming safer. From 2008 to 2013, the number of motorcyclists who had fatal accidents on Germany’s roads fell by 13 percent to 568. Experts believe that one reason for the decline is the spread of anti-lock braking systems. Summarizing the findings from the German In-Depth Accident Study GIDAS, Gerhard Steiger, president of the Bosch Chassis Systems Control division, says: “ABS is able to prevent a quarter of all motorcycle accidents resulting in death or injury.” This active safety system works to prevent wheels from locking. Motorcycles come to a far safer stop when braking hard or when braking on a slippery surface.

In the future, MSC motorcycle stability control will offer the best possible safety for motorcyclists. Developed by Bosch, the system records the current lean angle and adapts the ABS support and traction control to it. This means that it is especially useful in corners, which is where almost half of all fatal motorcycle accidents occur. “Like ESP in cars, MSC currently offers the best possible support, whether braking or accelerating, and even when the rider is leaning over at a steep angle,” Steiger says.

Maximum protection in critical situations
In 2013, 30 percent of all motorcycles produced in Europe featured ABS. At the end of 2013, the world’s first motorcycle stability control system first went into series production in the KTM 1190 Adventure and Adventure R. MSC technology is based on an ABS system including composite brake function, and also features a lean angle sensor. This measures the current lean of the motorcycle, allowing the system to adjust its braking and acceleration interventions to suit the lean angle. Precise regulation offers a smooth progression in brake pressure as the rider leans in for the corner, as well as boosting deceleration on the straight. And by analyzing tilt rate and linear acceleration, the system can tell sooner when the front or rear wheel is about to lift off, allowing MSC to intervene with a corrective action. Brake force is flexibly distributed between the front and rear wheel according to the driving situation, ensuring the safest possible deceleration. Further GIDAS analyses show that MSC can help in two thirds of the motorcycle accidents that occur in bends due to rider error.

From ABS light to MSC – a solution for every class of motorcycle
Having taken a modular approach, Bosch can offer brake control systems to suit any type of motorized two-wheeler that features a hydraulic brake. As a cost-effective solution especially for emerging markets such as India, ABS 9 light employs a single hydraulic brake channel to control the front wheel. With two channels, ABS 9 base offers anti-lock protection for the front and rear wheels. ABS 9 plus is particularly suited to high-performance machines. Even while pressure is building up during an emergency stop, the system already intervenes to prevent the motorcycle tipping forward. With the help of an additional pressure sensor, it detects early signs of the rear wheel leaving the ground. ABS 9 enhanced is the top-of-the-line version and offers the eCBS (electronic combined brake system) function. This means that all the rider has to do is apply one of the brakes, whether front or rear: ABS 9 enhanced then automatically activates the second brake to bring the optimum brake force to bear on both wheels without the rider having to apply any additional force on the brake lever and without any alteration in brake pressure. MSC, Bosch’s most comprehensive solution, builds on ABS 9 enhanced by employing a lean-angle sensor.

Weather plays a crucial role in the number of motorcycle accidents
Aside from technology, there is another factor that has a direct impact on the number of motorcyclists killed on the roads: the weather. Looking back over several years, it is clear that the number of motorcycle accidents always increases significantly when the weather is good. In April and May, the number of motorcyclists killed or severely injured seems particularly dependent on the weekend weather. When the sun comes out, many riders choose to make the most of the opportunity to go on their first outing – precisely when they are unpracticed and overconfident. The consequences are often fatal. In 2014, for instance, 37 motorcyclists were killed on Baden-Württemberg’s roads in the first five months of the year, while in the previous year, with its more wintry weather, the number for that same period was just 20. Whatever the weather conditions, ABS and MSC can provide comprehensive support, regardless of whether a bend that was entered too fast unexpectedly becomes tighter, whether a vehicle suddenly pulls out into the road ahead, or whether the road surface is wet or wet in patches.

EU makes ABS compulsory in all motorized two-wheelers from 2017 onwards
Each year around 5,000 motorcyclists die on Europe’s roads alone. Convinced by findings from surveys dedicated to the issue, in 2013 the EU introduced a requirement for all motorized two-wheelers with an engine displacement greater than 125cc to be equipped with an ABS system. The regulation applies to all newly registered motorcycles from 2017 onwards and for all motorcycles that go through type approval from 2016 onwards. Smaller two-wheelers with an engine displacement of over 50cc must also be equipped with ABS, or at least a “combined” braking system that brakes the other wheel when one brake is activated. However, such a system does not eliminate the possibility of wheels locking.

Further links:
Bosch automotive technology for two-wheelers:
YouTube video on motorcycle ABS:
YouTube video on motorcycle stability control:
YouTube-Video on motorcycle ABS for emerging countries:
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  • July 31, 2014
  • Press releases
  • Automotive technology
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