Flex fuel systems Versatile. Economical. Resource-friendly. clean & economical

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1 Flex fuel systems Versatile. Economical. Resource-friendly. clean & economical

2 Flex fuel systems for resource-friendly mobility Bosch flex fuel technology for two-wheelers, passenger cars, and light commercial vehicles Flex fuel systems 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 started developing and manufacturing flex fuel technology back in We comprehensively integrate our expertise and wealth of experience into the product portfolio for two-wheelers, passenger cars, and commercial vehicles. 0 In flex fuel systems, we partner with automakers to continuously develop the technology. Bosch flex fuel systems provide automakers with the potential to tap into new sectors of the economy. 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 percent of the market, while other markets still offer a great deal of potential for establishing these systems. And from a macroeconomic perspective, the use of flex fuel systems means less dependence on crude oil. Alternative fuel ethanol Alternative fuels contribute to more economical and 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 system Our flex fuel system is designed to operate reliably even from a cold start with a tank full of pure ethanol. Since ethanol combustion is problematic at temperatures below 13, vehicles with the Bosch flex fuel system are fitted with a small additional gasoline tank. On the basis of sensor data, the control unit can automatically switch to gasoline mode to ensure a reliable, comfortable start. Following 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 comfort at cold temperatures. During a cold start, electrically controlled heating elements in the fuel rail warm the ethanol to the required temperature. This improves the ethanol's vaporization and reduces the amount of fuel required for injection. Compared with conventional cold-start systems, Flexstart reduces CO₂ 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, and distributed for each combustion cycle. The result is lower fuel consumption and reduced emissions, coupled with increased engine power output. Thanks to consistent further development, our flex fuel systems can also be used in combination with gasoline direct injection. Flexstart system Flex fuel injector

3 Automotive competence from a single source: Bosch your partner for flex fuel systems Further information: can be found at 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, turbocharging, 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 production 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 customers 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 Fuel injectors for flex fuel systems Fuel injectors for flex fuel systems Vehicles with a flex fuel system run on a mixture of gasoline and bio ethanol. 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. EV6, HDEV5, EV14 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 Direct injection systems employ high-pressure injectors. These inject the fuel directly into the combustion chamber. 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 speci fically mixed in a certain region of the combustion chamber in order to obtain the best possible combustion of the mixture. 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.

5 Fuel injectors for flex fuel systems Technical features EV6 Linearity DFR 12 Droplet size Variants Noise Fuels Technical features µm (rsmd, reduced Sauter Mean Diameter) available Length, spray pattern db Gasoline, ethanol ( E100), methanol ( M15) EV14 Linearity DFR 13 Leakage Droplet size Variants Weight Fuels 1.8 mm 3 /min µm (rsmd, reduced Sauter Mean Diameter) available Geometry, spray pattern ~25 g Gasoline, ethanol ( E100), methanol ( M15) 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 mm 3 /min is a specific characteristic 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 HDEV5 The 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. Technical features System pressure Flow rate Leakage Fuels HDEV5 20 MPa Droplet size SMD (Sauter Mean Diameter) 15 µm Spray form Injector installation 25 cm 3 /s at 10 MPa < 2,5 mm 3 /min at 10 MPa Gasoline, ethanol: all fuel qualities worldwide Variable number and position of spray holes Central or lateral Robert Bosch GmbH Printed in P14G-C/CCA En Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights

6 Fuel rail for flex fuel systems Fuel rail for flex fuel systems The fuel rail receives the fuel from the fuel supply module and distributes it to the fuel injectors. It is important that the fuel has the required pressure at the start of the injection and that there are no pressure fluctuations between individual injections. Plastic variant Simplified logistics, assembly, and handling Ethanol resistance facilitates worldwide use Flexible installation/design 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 Vehicles with a flex fuel system run on a mixture of gasoline and bio ethanol. 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 injectors. These inject the fuel directly into the combustion chamber.

7 Fuel rail for flex fuel systems Fuel rail for the Flexstart system Because ethanol is harder to ignite at temperatures below 20 C, 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. Plastic variant The fuel rail receives the fuel from the fuel-supply module and distributes it to the fuel injectors. It is important that the fuel has the required pressure at the start of the injection and that there are no pressure fluctuations between individual injections. Reliable engine start with E85/E100 without an additional gasoline tank Improved driveability during engine warm-up 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. Technical features Operation mode Temperature output between the injectors < 10 C Rate of heating Fuel temperature Variants Fuel rail for the Flexstart system 4- or 3-cylinder operation 30 C/s C (depending on system pressure) Plastic or stainless steel 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) Robert Bosch GmbH Printed in P14J-C/CCA En Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

8 Electronic control unit Motronic for flex fuel systems Electronic control unit for flex fuel systems The electronic control unit for flex fuel systems processes 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. u One single, scalable ECU family for different markets and vehicle segments u Potential for extended functionality u Flexible integration of customer software Vehicles with a flex fuel system run on a mixture of gasoline and bio ethanol which enables up to 40% lower CO 2 output than gasoline operation. 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. Additionally the control unit can control the Flexstart system which warms the fuel and ensures a smooth engine start at low temperatures even with high-ethanol fuels. Depending on ethanol content and ambient temperature the electronic control unit triggers the heating elements in the fuel rail via the heating control unit. The electronic control unit variants feature: u A common platform for gasoline, flex fuel, CNG and diesel control units u Diagnostics functions, e.g. for compliance with emissions legislation u Infineon 32 bit microcontroller u Standardized communication interfaces (CAN, Flexray, SENT, LIN, K-LINE) u Highly scalable software and hardware, 4-fold computing power from basic segment to high end u Standardized formats to support software sharing and global development (AUTOSAR, MSR) 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 Printed in P142-C/CCA En Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

9 Heating control unit for the Flexstart system Heating control unit for the Flexstart system The heating control unit monitors the heat energy delivered in four separate heat circuits. It measures the supplied temperature and sends this data back to the engine control unit together with diagnostics information. u Reliable engine start with E85/E100 even at low ambient temperature u Improved driveability during engine warm-up The heating control unit is characterized by: u Four individually controlled heating circuits with 260 W at 12 V each u Precise energy control u Integrated current sensor u Reverse polarity protection u Full diagnostics: open/short circuit; switching elements (FETs) u Internal overtemperature cutoff u Determination of the operating mode air or vapor (in combination with heating element GLP2-FS) Vehicles with a flex fuel system run on a mixture of gasoline and bio ethanol. 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. Because ethanol is harder to ignite at temperatures below 20 C, 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. 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 Printed in P14N-C/CCA En Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

10 Heating element for the Flexstart system Heating element for the Flexstart system 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: u Resistance against E100 u Determination of the operating mode air or vapor (in combination with the heating control unit HCU) u Reliable engine start with E85/E100 even at low ambient temperature u Improved driveability during engine warm-up Vehicles with a flex fuel system run on a mixture of gasoline and bio ethanol. 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. Because ethanol is harder to ignite at temperatures below 20 C, 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. The heating element is there to ensure a comfortable and clean engine start when using high-ethanol fuels at temperatures below 20 C. Flexstart replaces systems which use gasoline to start the engine and therefore require an additional tank. Robert Bosch GmbH Printed in P14L-C/CCA En Robert Bosch GmbH All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights

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