Mappe Flex Fuel En

7/24/2019 Mappe Flex Fuel En

1/11

Flex fuel systems

Versatile. Economical. Resource-friendly.

clean &economical


2/11

Flex fuel systems forresource-friendly mobility

Flex fuel systems

Tapping into market potential

For many end customers the choice of fuel is the

decisive purchase argument for vehicles with

flex fuel technology. In Brazil for instance, these

vehicles already account for more than 80 per-

cent of the market, while other markets still offer

a great deal of potential for establishing these

systems. And from a macroeconomic perspec-

tive, the use of flex fuel systems means less de-

pendence on crude oil.

Alternative fuel ethanol

Alternative fuels contribute to more economicaland resource-friendlier mobility. Ethanol has

established itself as a fuel particularly with flex

fuel systems; it can be mixed with conventional

gasoline in proportions of between five and

100 percent. Countries such as China are also

using methanol as a fuel.

Until now, ethanol has tended to be distilled

from sugar cane or cereals containing starch.

New technologies are based on the use as

biomass of cellulosic raw materials such as

miscanthus. The use of algae is also being

looked into. So as not to use up arable land,

such algae could be cultivated in offshore parks,

for example.

Flex fuel vehicles come with an injection system that can be operated

with gasoline, a mixture with various ratios of gasoline and ethanol, or

pure ethanol.

End customers thus have a flexible choice of fuel, are less dependent

on having access to one fuel in particular, and can respond directly to

price developments.

Bosch flex fuel systems

provide automakers

with the potential to tap

into new sectors of the

economy.

0

Bosch flex fuel technology for two-wheelers,passenger cars, and light commercial vehicles

Flex fuel system

Our flex fuel system is designed to oper-

ate reliably even from a cold start with a

tank full of pure ethanol. Since ethanol

combustion is problematic at tempera-

tures below 13 , vehicles with the Bosch

flex fuel system are fitted with a small ad-

ditional gasoline tank. On the basis of

sensor data, the control unit can auto-

matically switch to gasoline mode to en-

sure a reliable, comfortable start. Follow-

ing a brief warm-up phase, the system

switches back to ethanol mode.

Flexstart system

Our innovative Flexstart system, which

dispenses with the additional gasoline

tank, provides even more starting com-

fort at cold temperatures. During a cold

start, electrically controlled heating ele-

ments in the fuel rail warm the ethanol to

the required temperature.

Bosch started developing and manufacturing flex fuel technology back in

1986. We comprehensively integrate our expertise and wealth of expe-

rience into the product portfolio for two-wheelers, passenger cars, and

commercial vehicles.

In flex fuel systems, we partner with automakers to continuously develop

the technology.

This improves the ethanol's vaporization

and reduces the amount of fuel required

for injection.

Compared with conventional cold-start

systems, Flexstart reduces CO emissions

by around two percent and HC emissions

by up to 30 percent.

Flex fuel gasoline direct injection

Direct injection offers additional benefits

over gasoline port fuel injection. Air and

fuel are precisely metered, prepared, anddistributed for each combustion cycle.

The result is lower fuel consumption and

reduced emissions, coupled with in-

creased engine power output. Thanks to

consistent further development, our flex

fuel systems can also be used in combi-

nation with gasoline direct injection. Flex fuel injector

Flexstart system


3/11

Further information can be found at

www.bosch-pfi.com

Further information:

www.bosch-flexfuel.com

Automotive competence from a single source:Bosch your partner for flex fuel systems

Comprehensive portfolio and extensive expertise

Our portfolio includes flex fuel systems for two-wheelers, passenger cars, and

light commercial vehicles, as well as for a range of vehicle functions including

fuel supply, fuel injection, air management, ignition, engine management, turbo-

charging, thermal management, exhaust-gas treatment, transmission technology,

and start-stop. Components for the Flexstart system and gasoline direct injection

supplement the product range.

System and network competence

Bosch boasts a holistic understanding of drive systems including knowledge of

the many technical influencing factors, interrelationships, and dependencies of a

flex fuel system. System networking using intelligent software ensures optimum

functionality even with changing fuel-mixture ratios.

Innovation driver and technology leader

We develop flex fuel technology to high-quality, reliable large-scale series pro-duction standards. The Brazilian Ministry of Science and Technology presented

us with the Technological Innovation Finep Award in recognition of this work.

Ensuring quality and reliability

Our portfolio for flex fuel vehicles meets the most stringent technical performance

requirements and offers a high degree of functional safety and reliability even

when used with poor-quality fuels.

Global presence

Bosch has production and development experts on hand around the globe near to

automakers. We are familiar with specific local requirements and help our cus-

tomers tap into new markets.

Long-term partnership

Bosch provides automakers with end-to-end support for their flex fuel activities:

from designing new vehicle concepts, their development and application, through

series production, to vehicle servicing.


4/11

Gasoline SystemsFuel injectors for flex fuel systems

Vehicles with a flex fuel system run on a mixture of

gasoline and bioethanol. The proportion of ethanol

can vary from 5% (E5) to 100% (E100). The Bosch

portfolio encompasses flex fuel systems for port fuel

injection and for direct injection.

Port fuel injection systems prepare the air-fuel mixture

in the intake manifold. The fuel rail distributes the fuel

to the fuel injectors which atomize the fuel into the

intake air flow.

Direct injection systems employ high-pressure injec-

tors. These inject the fuel directly into the combustion

chamber.

Task

With port fuel injection, the fuel injector is responsible

for injecting the fuel into the intake manifold so that

it forms a homogeneous mixture with the intake air;

this mixture is fed into the most favorable area of the

combustion chamber to provide optimum combustion.

The aim is to prevent excessive fuel condensation on

the wall from the intake manifold or intake valve.

The high-pressure injector meters and atomizes the

fuel so that fuel and air are specifically mixed in acertain region of the combustion chamber in order to

obtain the best possible combustion of the mixture.

Function

The fuel injector is a solenoid valve which is used to

control the injection start and duration. The shape

of the fuel spray is determined for each engine by

the position of the injector and the configuration and

number of orifices.

Customer benefits

Reduced emissions

Improved spray preparation

Flexible installation and spray characteristics

for every engine

Savings potential in engine compartment

insulation

Ethanol resistance facilitates worldwide use

Meets requirements for engine downsizing

(advanced spray point)

Additional fuel efficiency and emissions

reduction potential with direct injection

Fuel injectors for flex fuel systems

EV6, HDEV5, EV14


5/11

Robert Bosch GmbH

Gasoline Systems

Postfach 30 02 40

70442 Stuttgart

Germany

www.bosch-automotivetechnology.com

Printed in Germany

292000P14G-C/CCA-201309-En

Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction,

editing, distribution, as well as in the event of applications for industrial property rights

Variant: fuel injector EV6

The low-noise fuel injector EV6 is available in a large

variety of variants with different lengths and spray

patterns. Linearity is very good with a large Dynamic

Flow Range (DFR) up to 12.

Variant: fuel injector EV14

Low leakage below 1.8 mm3/min is a specific charac-

teristic of the slim and lightweight EV14 injector.

It has been developed as a global injector which is

manufactured locally in all markets worldwide and

it is also suitable for use with flex fuel. The linearity

range is even higher than that of the EV6. The large

variant frame comprises various geometries and

spray patterns.

Variant: high-pressure fuel injector HDEV5The HDEV5 high-pressure fuel injector meters and

atomizes the fuel with high pressure directly into the

combustion chamber. The inward-opening multihole

injector features high variability concerning spray

angle and spray shape. Variable lengths are available

as options for different installation requirements.

Gasoline Systems | Fuel injectors for flex fuel systems

Technical features

EV6

Linearity DFR 12

Droplet size 50130 m (rSMD, reduced

Sauter Mean Diameter)

available

Variants Length, spray pattern

Noise 5153 dB

Fuels Gasoline, ethanol ( E100),

methanol ( M15)

Technical features

EV14

Linearity DFR 13

Leakage 1.8 mm3/min

Droplet size 50130 m (rSMD, reduced

Sauter Mean Diameter)

available

Variants Geometry, spray pattern

Weight ~25 g

Fuels Gasoline, ethanol ( E100),

methanol ( M15)

Technical features

HDEV5

System pressure 20 MPa

Flow rate 25 cm3/s at 10 MPa

Leakage < 2,5 mm3/min at 10 MPa

Fuels Gasoline, ethanol:

all fuel qualities worldwide

Droplet size SMD

(Sauter Mean Diameter) 15 m

Spray form Variable number and position

of spray holes

Injector installation Central or lateral


6/11

Gasoline SystemsFuel rail for flex fuel systems

Task

The fuel rail receives the fuel from the fuel supply mod-

ule and distributes it to the fuel injectors. It is impor-

tant that the fuel has the required pressure at the start

of the injection and that there are no pressure fluctua-

tions between individual injections.

Function

The fuel injectors are mounted on the fuel rail. This

self-damping fuel rail is made out of plastic tailored for

use with ethanol, or out of stainless steel. It features a

highly versatile design and configurations:

Feed line with customer specific connections

Available with our without return line

Available with all variants of the EV14 or EV6/EV6P

in ethanol resistant versions


gasoline and bioethanol. The proportion of ethanol

can vary from 5% (E5) to 100% (E100). The Bosch

portfolio encompasses flex fuel systems for port fuel

injection and for direct injection.

Port fuel injection systems prepare the air-fuel mixture

in the intake manifold. The fuel rail distributes the fuel

to the fuel injectors which atomize the fuel into the

intake air flow.

Direct injection systems employ high-pressure injec-

tors. These inject the fuel directly into the combustion

chamber.

Customer benefits

Simplified logistics, assembly, and handling

Ethanol resistance facilitates worldwide use

Flexible installation/design

Fuel rail for flex fuel systems

Plastic variant


7/11

Robert Bosch GmbH

Gasoline Systems

Postfach 30 02 40

70442 Stuttgart

Germany


Printed in Germany

292000P14J-C/CCA-201309-En


editing, distribution, as well as in the event of applications for industrial property rights.

Because ethanol is harder to ignite at temperatures

below 20C, Bosch has developed the Flexstart System

to warm the fuel during the starting phase. Flexstart

replaces systems which use gasoline to start the

engine and therefore require an additional tank.

Task

The fuel rail receives the fuel from the fuel-supply mod-

ule and distributes it to the fuel injectors. It is impor-

tant that the fuel has the required pressure at the start

of the injection and that there are no pressure fluctua-

tions between individual injections.

The Flexstart system warms the fuel and ensures a

smooth engine start at low temperatures even with

high-ethanol fuel. Depending on ethanol content and

ambient temperature Flexstart warms the ethanol

using heating elements in the fuel rail controlled by

the engine control unit via the heating control unit.

Function

The fuel injectors are mounted on the fuel rail. This

self-damping fuel rail has been tailored for use with

ethanol. Its specific features are:

Resistant with E100 operation

Determination of the operating mode air or vapor (in

combination with heating element GLP2-FS GLP2-FK

and heating element HCU)

Gasoline Systems | Fuel rail for flex fuel systems

Customer benefits

Reliable engine start with E85/E100 without

an additional gasoline tank

Improved driveability during engine warm-up

Fuel rail for the Flexstart system

Technical features

Fuel rail for the Flexstart system

Operation mode 4- or 3-cylinder operation

Temperature output

between the injectors < 10C

Rate of heating 30C/s

Fuel temperature 70125C (depending on

system pressure)

Variants Plastic or stainless steel

Plastic variant


8/11

Gasoline SystemsElectronic control unitMotronic for flex fuel systems

Function

The electronic control unit for flex fuel systems pro-

cesses input data from sensors located throughout

the drivetrain. It detects which fuel is being used

and adjusts the engine management accordingly. At

higher ethanol content, for instance, the air-fuel ratio

is reduced.

Additionally the control unit can control the Flexstart sys-

tem which warms the fuel and ensures a smooth engine

start at low temperatures even with high-ethanol fuels.

Depending on ethanol content and ambient tempera-

ture the electronic control unit triggers the heating

elements in the fuel rail via the heating control unit.

The electronic control unit variants feature:

uA common platform for gasoline, flex fuel, CNG

and diesel control units

uDiagnostics functions, e.g. for compliance with

emissions legislation

uInfineon 32 bit microcontroller

uStandardized communication interfaces (CAN,

Flexray, SENT, LIN, K-LINE)

uHighly scalable software and hardware, 4-fold

computing power from basic segment to high end

uStandardized formats to support software sharingand global development (AUTOSAR, MSR)

Customer benefits

uOne single, scalable ECU family for different

markets and vehicle segments

uPotential for extended functionality

uFlexible integration of customer software


gasoline and bioethanol which enables up to 40%

lower CO2output than gasoline operation. The propor-

tion of ethanol can vary from 5% (E5) to 100% (E100).

The Bosch portfolio encompasses flex fuel systems for

port fuel injection and for direct injection.

Task

The aim of the electronic control unit is to provide the

required engine torque with minimal fuel consumption

and emissions. It controls mixture formation (air mass,

injected fuel amount, injection timing), ignition and the

exhaust-gas treatment.

Robert Bosch GmbH

Gasoline Systems

Postfach 30 02 40

70442 Stuttgart

Germany


Printed in Germany

292000P142-C/CCA-201309-En



Electronic control unit for flex fuel systems


9/11

Gasoline SystemsHeating control unit for theFlexstart system

Function

The heating control unit monitors the heat energy de-

livered in four separate heat circuits. It measures the

supplied temperature and sends this data back to the

engine control unit together with diagnostics informa-

tion.

The heating control unit is characterized by:

uFour individually controlled heating circuits

with 260 W at 12 V each

uPrecise energy control

uIntegrated current sensor

uReverse polarity protection

uFull diagnostics: open/short circuit; switching

elements (FETs)uInternal overtemperature cutoff

uDetermination of the operating mode air or vapor

(in combination with heating element GLP2-FS)

Customer benefits

uReliable engine start with E85/E100 even at

low ambient temperature

uImproved driveability during engine warm-up


gasoline and bioethanol. The proportion of ethanol can

vary from 5% (E5) to 100% (E100). The Bosch portfo-

lio encompasses flex fuel systems for port fuel injec-

tion and for direct injection.


below 20C, Bosch has developed the Flexstart system




Task

The heating control unit monitors the heating of the

fuel in order to ensure a fast, comfortable and clean

engine start. Flexstart replaces systems which use

gasoline to start the engine and therefore require an

additional tank.

Robert Bosch GmbH

Gasoline Systems

Postfach 30 02 40

70442 Stuttgart

Germany


Printed in Germany

292000P14N-C/CCA-201309-En



Heating control unit for the Flexstart system


10/11

Gasoline SystemsHeating element for theFlexstart system

Function

The heating element dissipates heat to the fuel within

the fuel rail, so the fuel has the right temperature

when it is injected. The material of the heating element

has been specifically selected for operation with high

surface temperature, while it is immersed in the fuel.

Its rated output is 260 W at 12 V.

The heating element is characterized by:

uResistance against E100

uDetermination of the operating mode air or vapor

(in combination with the heating control unit HCU)

Customer benefits

uReliable engine start with E85/E100

even at low ambient temperature

uImproved driveability during engine warm-up


gasoline and bioethanol. The proportion of ethanol can

vary from 5% (E5) to 100% (E100). The Bosch portfo-

lio encompasses flex fuel systems for port fuel injec-

tion and for direct injection.


below 20C, Bosch has developed the Flexstart system




Task

The heating element is there to ensure a comfortable

and clean engine start when using high-ethanol fuels at

temperatures below 20C. Flexstart replaces systems

which use gasoline to start the engine and therefore

require an additional tank.

Robert Bosch GmbH

Gasoline Systems

Postfach 30 02 40

70442 Stuttgart

Germany


Printed in Germany

292000P14L-C/CCA-201309-En


editing, distribution, as well as in the event of applications for industrial property rights

Heating element for the Flexstart system


11/11

Robert Bosch GmbH

Gasoline Systems

Postfach 30 02 40

70442 Stuttgart

Germany

www.bosch-flexfuel.com

Printed in Germany

2 920 00P 0ZU-C/CCA-201304-En

Documents

Mappe Flex Fuel En