Bosch injection technology in the Freightliner Cascadia delivers 1,200 bar system pressure
Up to 5 percent lower fuel consumption with the smart assistance system Eco.Logic motion
Bosch truck technology: from powertrain technology to instrument clusters to power steering
In the dark skies over Texas, the turban’s orange glow stands out. Normally people around here wear a cowboy hat, but Jaspreet Bola knows more about horsepower than he does about horse riding – and anyway, he prefers to stick to his own traditions. It’s eight in the morning as this young Sikh climbs out of the cab of his semi tractor-trailer. In this grey, wet weather at a truck stop outside Dallas, it’s time for a quick coffee, a soda, and a burger. He’ll be choosing the chicken and avoiding the beef – and the same goes for his copilot, Manjinder Sidhu, who has no cowboy hat either, but instead a blue and white knit cap. The Texas Longhorn cattle quietly grazing on the horizon have nothing to fear from this pair. Jaspreet and Manjinder come from Punjab, a region in northern India, but have both lived in Canada for many years. Every week, their job as truckers sees them driving thousands of miles through North America’s varied landscapes. Day and night. One drives while the other sleeps. They almost always take the same route: from Toronto, Canada’s biggest city, to Laredo, in the far south of the United States.
Bosch warehouse in Laredo handles around 100 trucks daily There they head for the Bosch warehouse, which stretches over more than 11,000 square meters and is just a stone’s throw from the Mexican border. The pale yellow building is one of the Bosch logistics hubs for North America. Some 750,000 pallets pass through here every year, and the site handles around 100 trucks daily. “It takes no time at all,” says Jaspreet, “you just reverse up to the ramp, unload the raw materials, fill up with finished components, and an hour later you’re back on the road.” This time, too, Jaspreet and Manjinder are transporting nuts and bolts, plastic parts, and seals made in the United States and Canada to Laredo. There, together with similar components, they are readied for onward transportation to Bosch’s Mexican plants, and generally spend no more than 24 hours in the warehouse. Heading back north, Jaspreet and Manjinder’s truck is loaded with finished products from Toluca, San Luis Potosí, and Aguascalientes: ignition coils, wiper systems, brake components, sensors, and much more – most of them destined for the big automakers in and around Detroit.
Up to 1,200 bar injection pressure for efficient combustion But these two truckers don’t just have Bosch technology in their cargo hold. It’s also under the hood of their Freightliner Cascadia Evolution. The truck is powered by a Detroit DD15 engine with six cylinders, around 500 HP, almost 15 liters displacement – and the highly efficient Bosch CRSN4 common-rail injection system. The high-pressure pump and rail come from the Jihlava plant in the Czech Republic, while the extremely precise injector is manufactured in Homburg, Germany. “The Freightliner has plenty of power, uses less fuel than other trucks, and is nice and quiet,” Manjinder says. The pump provides system pressure of up to 1,200 bar, while the injector features an integrated hydraulic pressure amplifier that can more than double the maximum injection pressure. As a result, the engine is economical, and efficient – and provides power whenever it is needed. And this not only in the Cascadia, but also in millions of commercial vehicles in North America and the rest of the world.
But back on the soaking wet parking lot in Texas, thoughts such as this are not the issue. Jaspreet and Manjinder prefer to spend their time working out how long it will take them to reach Laredo – and above all whether they will manage to get back to Toronto in time for Diwali, the Indian festival of light. They’ve already put around two-thirds of the journey behind them. “We reckon on roughly 34 hours each way,” Manjinder says. There are rarely any traffic jams, they fill up just once, and the mandatory rest periods aren’t too long when there are two drivers. They know the route like the back of their hands: 2,948 kilometers through the southern tip of Canada, crossing into the U.S. near Detroit, then across the industrial heartlands of Michigan and Ohio, straight through the fields and forests of Indiana and Illinois, and over the Mississippi to Missouri. And when the sky gets bigger and the light changes, and when it’s banjos and not guitars on the radio, that’s when they’ve arrived in the South: welcome to Texas. Now Canada is a long way away.
Doesn’t it get boring? Always taking the same highways and stopping at the same gas stations? Jaspreet laughs. “It depends on whether there’s something to look forward to,” he says. For him there is: he dreams of having a small house in the suburbs of Toronto and of marrying his girlfriend. That’s what he’s saving up for, regularly putting a little money aside. He and Manjinder are two of a great many truckers with Indian roots who drive for Canadian logistics companies. “People consider us Sikhs honest and reliable,” says Kashmir Singh, one of Jaspreet and Manjinder’s fellow truckers. Kashmir has been driving all over North America for many years and has already been to all 48 contiguous U.S. states. Like the other two, he now works for himself, driving his own truck, despite the Giggs Express logo on its side. Giggs Express is the company that sent the three drivers on their current journeys. Independent drivers are paid by the mile, which means they are directly affected by the price of diesel. Each time the price goes up, Jaspreet’s house in the suburbs recedes another few months into the future.
Bosch Eco.Logic.motion can reduce fuel consumption by 5 percent What the drivers need, therefore, is more economical engines. That’s why Jaspreet’s brother – who owns the truck – opted for the Freightliner. Not only does it feature state-of-the-art Bosch diesel technology, it also has Eco.Logic motion, the smart assistance system provided by Bosch’s Car Multimedia division. This system makes use of a digital map and knows long before the driver does whether the road is going uphill or downhill, and whether to expect a bend or a long stretch of straight road. Because the system also detects the current speed and the selected gear, it can work with the automatic transmission to accelerate in advance or avoid unnecessary gearshifts – without the driver having to do anything. Eco.Logic motion can potentially reduce fuel consumption by 5 percent. “Every liter less helps,” Jaspreet says, filling up for a few hundred dollars somewhere in deepest Missouri. All the drivers agree that diesel will remain the most important powertrain in the logistics business for the foreseeable future. That makes it all the more important to further improve internal-combustion engines and make them more efficient, and more cost-effective. Bosch is working hard on this – so Kashmir, Manjinder, and millions of other truckers don’t have to fill up so often. To reduce environmental impact. And to help Jaspreet’s dream of a wedding and a house come true that little bit sooner...
Bosch concepts and technologies for today’s and tomorrow’s trucks American powertrain: The Freightliner’s diesel engine features Bosch injection technology. The CRSN4 common-rail system ensures optimum performance, low fuel consumption, and reduced emissions.
Heavily automated: At some point, heavy-duty trucks will also be largely automated and connected. The steering system will play a major part in achieving this. Robert Bosch Automotive Steering GmbH, the world’s biggest manufacturer of power steering systems, already offers Servotwin®, the first integrated electro-hydraulic steering system for heavy-duty trucks (not installed in the truck presented in this article). This steering system allows precise steering actions at high speeds as well as comfortable truck maneuvering at low speeds. As Servotwin® is developed further, it will bring to trucks many of the assistance systems that have already proved so valuable in cars. These include corrective steering interventions should the vehicle unintentionally leave its lane and a traffic jam assistant that relieves drivers of a lot of stress. It can also support an assistance function that determines how much steering has to be corrected to counter a sudden gust of wind, and actuates an electric motor to help with the maneuver.
Digital exterior mirror: Lower fuel consumption – the large-surface exterior mirror that increases drag is a thing of the past. On top of that, drivers have a much better view of what’s happening to the rear, even at night.
Freely programmable instrument cluster: The days of fixed mechanical instrument clusters are over. Today’s displays can be adapted to the traffic situation and to the requirements of drivers and automakers. The extremely high-resolution display allows information to be presented more accurately.
Display unit: The display unit is the central user interface for navigation and entertainment. Drivers can connect it directly with their smartphones, and in this way safely operate many apps on their truck’s touchscreen. The display’s design and interface dynamically adapt to the driving situation.
Contact person for press inquiries: Florian Flaig phone: +49 711 811-6282
Dedicated organization is in charge of sales and system development
More than diesel injectors: color displays and sensors part of new portfolio
As the top management of Bosch thought long and hard about new strategic business fields, the field of commercial vehicle and off-road (CVO) was still no more than a promising idea. Market studies showed that it was more than that. In this segment, encompassing trucks and 4000 hp construction machines, forklifts and harvesters, there is a potential for growth in the billions of euros in countries with increasingly strict environmental and safety regulations as well as in emerging regions with cities whose populations are rapidly exceeding the one million mark.
To date, Bosch has not been able to tap the full potential of the market because of its organizational structure. Left to their own devices, most of the divisions struggled to offer CVO customers tailored solutions. At the beginning of this year, a stand-alone, effective unit was created for the commercial and off-road vehicle field.
The associates are not only focusing on major customers, but also paying attention to the entire spectrum of customers in the area, including small providers.
“We are not a division and are not comparable to any other known structure from the Mobility Solutions business sector,” says Johannes-Jörg Rüger, head of the organization. The new unit is rather a “sales organization with integrated system development” that closely cooperates with all the divisions.
Marketing director Anton Beer sees the following advantages: As a cross-divisional organization, CVO can offer the customer “big-picture solutions.” “If the customer wants to increase their efficiency, we don’t just look at the injection system,” Beer explains. “We consider all the applications. That requires the support of multiple divisions.” Such as replacing a rear-view mirror with a camera system and display.
A contact for every customer It’s no longer enough to provide agricultural machine manufacturers with diesel injection systems – they also need color displays or sensors to assist drivers. That’s why there will be one specific contact person per Bosch customer in the future – for the whole Bosch product range. That’s already the case in the passenger car sector – manufacturers such as Daimler or VW have always had their own salespeople.
Nevertheless, CVO is not simply a sales organization; it is also active in system development. “This could include products in the passenger car sector, such as a stereo video camera tailored to suit the commercial vehicle market with the help of the other divisions. But it could also include our own products,” Beer says. In particular, the topics of networking and automated driving are promising areas for synergies with the passenger car sector, which could potentially spark significant sales growth.
In light of the lower quantities in the off-road business, this sector can occasionally appear to be less attractive at first glance than the passenger car business, Rüger notes. “However, our projects tend to run longer – so it’s worth taking a second look.”
Bosch CEO Dr. Volkmar Denner: “Anton van Zanten and his engineering colleagues are the guardian angels of many drivers.”
To date, ESP has saved more than 8,500 lives in Europe alone.
After the seat belt, ESP is the most important vehicle safety system.
Anti-skid protection already features in 64 percent of all new vehicles worldwide.
Stuttgart, Germany/Lisbon, Portugal – Today in Lisbon, Anton van Zanten was honored for his invention of the ESP electronic stability program with the 2016 European Inventor Award. The award, which is conferred by the European Patent Office (EPO), was presented to him in the “Lifetime achievement” category. The Dutch native developed the anti-skid system as the head of a 35-member research group at Bosch, during a career that spanned more than 25 years. The system was first featured as standard equipment in the Mercedes-Benz S600 in 1995. “Anton van Zanten and his engineering colleagues are the guardian angels of many drivers,” said Dr. Volkmar Denner, the chairman of the board of management of Robert Bosch GmbH, in praise not only of the award-winner, but also of the team effort behind the innovation. “The invention of ESP stands for our ‘Invented for life’ ethos like few others,” the Bosch CEO said. In Europe alone, ESP has saved more than 8,500 lives and prevented more than a quarter of a million traffic accidents to date. That makes anti-skid protection the most important vehicle safety system after the seat belt – more important even than the airbag.
ESP is standard equipment in vehicles in a growing number of countries Using smart sensors, ESP compares 25 times per second whether the car is actually moving in the direction that the driver is steering it in. If the measured values do not match, the anti-skid system intervenes, initially reducing engine torque. If that is not sufficient, it additionally brakes individual wheels, generating the counterforce needed to keep a vehicle safely on course. If all vehicles were equipped with the anti-skid system, up to 80 percent of all skidding accidents could be prevented. Since November 1, 2014, ESP has been mandatory within the European Union for all newly registered cars and light commercial vehicles weighing up to 3.5 metric tons. In addition to the EU, the anti-skid system is also mandatory in Australia, Canada, Israel, New Zealand, Russia, South Korea, Japan, Turkey, and the United States. Worldwide, 64 percent of all new vehicles are therefore already equipped with ESP. Bosch has manufactured more than 150 million ESP systems to date.
Career with many inventions and awards By inventing the electronic stability program, Anton van Zanten and his development team at Bosch did more than just lay the foundation for greater road safety. The system is also the basis for today’s driver assistance systems and automated driving. Increasing automation presents an opportunity to lower accident rates even further – by up to a third in Germany alone. ESP is Anton van Zanten’s greatest success, but by far not his only achievement. The 75-year-old is the very epitome of an inventor. During his career as an automotive engineer, he was responsible for some 180 patent families. Along with ESP, his inventions include electronic rollover mitigation and trailer sway mitigation. Anton van Zanten entered into active retirement in 2003. To this day, he continues to lecture on vehicle systems at universities and act as a consultant for automotive companies. For his contributions to automotive safety, Anton van Zanten has already received numerous awards. However, the European Inventor Award, which pays tribute to his life’s work, is of particular significance.
Eleventh edition of the European Inventor Award in five categories The European Inventor Award has been presented since 2006. It is the EPO’s way of honoring researchers, scientists, technicians, and inventors whose inventions have been patented by the EPO and have made an outstanding contribution to scientific, technical, and social progress. What makes it unusual is that any member of the public can nominate an inventor for the award. From the nearly 400 nominees from a total of 13 countries in 2016, an independent, international jury selected the 15 finalists. The jury also decides the winners in the five categories “Industry,” “Small and medium-sized enterprises (SMEs),” “Research,” “Non-European countries,” and “Lifetime achievement.” The winners of the European Inventor Award receive a trophy shaped like a sail as a symbol of discovery and human ingenuity. The trophy is crafted with new materials every year.
Contact person for press inquiries: Jörn Ebberg, phone: +49 711 811-26223
Bosch develops electric powertrain for motorsport kart prototype together with FIA and German Motorsport Association
48-volt system makes karting emissions-free, quiet, and agile
Bosch series production technology powers the electric racing kart
“Electrification will bring more excitement, driving pleasure, and greater efficiency to motorsport,” says Dr. Markus Heyn, member of the board of management of Robert Bosch GmbH
Abstatt/Berlin – It goes from 0 to 100 kph under five seconds and has a top speed of over 130 kph, and with peak torque available even at low engine speeds, it can squeal the tires with just a tap of the pedal. The only things missing here are the engine roar and the smell of gasoline in the air. This is the motorsport experience that FIA Electric, the New Energy Commission, and the German Motorsport Association (DMSB) are presenting on May 21, 2016 in Berlin. Within the greater context of FIA Formula E they are showcasing the study of a purely electric racing kart prototype. The FIA and DMSB rely on Bosch for this innovative powertrain system. The supplier of technology and services developed the system together with these motorsport organizing bodies, as well as with Germany's largest kart manufacturer Mach 1 Kart. Together these organizations will be presenting an initial prototype in Berlin. “With this electric kart, the FIA, DMSB, and Bosch are together laying the foundations for 'electrifying' performance kart racing. Just as it has on the roads, electrification will bring more excitement, driving pleasure, and greater efficiency to race tracks,” says Dr. Markus Heyn, member of the board of management of Robert Bosch GmbH. DMSB General Secretary Christian Schacht is also enthusiastic about the electric racing kart: “We're happy to support the forward-looking and exciting FIA electric kart project. As an advanced technology nation, Germany very much has a special obligation to support electromobility in motorsports. We do that with Formula E, and we also do that by supporting junior kart racing drivers.”
Powertrain technology from the street to the race track Karting is considered to be the gateway series into the world of professional motorsport. Currently, most racing karts are powered by internal-combustion engines. When the FIA, DMSB, Mach 1 Kart, and Bosch decided to develop an all-new electric powertrain for professional karting, they logically began with a blank sheet of paper. The idea was to create a purely electric motorsport discipline that made no compromises in power or performance. Bosch motorsport engineers came up with a solution in the form of the new BRS boost recuperation system, whose first generation will go into production at the company starting in 2017. The electrical components of the BRS support the internal-combustion motor in compact vehicles with up to 10 kW of additional power, which reduces fuel consumption and CO2 emissions by up to 15 percent on the street. It also provides the internal-combustion engine with an additional 150 newton meters of torque during acceleration. “We have modified the system for use in professional karting, and we are using it it to electrically power the kart prototype,” says Dr. Klaus Böttcher, vice president of Bosch Motorsport. “We offer a complete system combining Bosch automotive large-scale production technology with specially developed components and powertrain control software from a single source.” Two starter-generators delivering a total output of 20 kW form the basis of the new powertrain, which sends a sporting 300 Nm of torque to the rear axle. Energy is stored in the system using a 48-volt lithium battery. In addition, the starter-generators can recover energy during recuperation and then use it for acceleration. The nerve center of the powertrain is a custom ECU that controls energy flows throughout the kart. A set of sensors and a wiring harness complete the overall system. The new electric powertrain turns the Mach 1 Kart chassis into a clean, fast, and agile performer on the race track. “Even during its initial run, the electric kart was able to hit 100 kph in less than five seconds and achieve a top speed of over 130 kph. Over the coming weeks and months we will continue testing to further explore the capabilities of the new electric kart,” explains Böttcher.
Bosch Motorsport With more than 100 associates around the world, Bosch Motorsport has been a part of Bosch Engineering, a subsidiary specializing in engineering services, since 2003. Bosch Motorsport engineers equip teams running in the DTM, FIA European Formula 3 Championship, the Porsche Carrera Cup Germany, and numerous rallies and long-distance championships – including the legendary 24 Hours of Le Mans event and of course the ultimate formula racing series – with race-tested technology made by Bosch. Bosch's involvement in motor racing dates back 115 years: the first racing victories with Bosch technology on board came in the early 1900s, and the motorsport success stories continue to this day.