Vehicle Systems Development, Vehicle Control Unit, Electric Powertrain, Fuel Cell, High-voltage DC-to-DC Converter and Charging Systems, Battery
Electrified mobility today offers solutions for wide-ranging requirements, from urban driving with zero local emissions to the extra power boost for a sporty driving style to noise-free and emission-free logistics. To optimally tailor the powertrain systems of the future to the respective requirements, it is important to precisely understand each particular use case as well as the associated objectives.
Bosch Engineering will be delighted to assist you with analyzing your requirements at both the system and component level. We will develop the optimal end-to-end solution for your specific application scenario. When doing so, however, we do not limit ourselves to just the powertrain system; rather, we take a holistic, cross-domain approach that considers the vehicle as a whole – for example, in the context of regenerative braking or vehicle dynamics. To this end, we make full use of the broad experience we have gained from different mobility markets and from the applications we have helped to develop through our involvement and assistance at all stages of the engineering project, from the initial prototype phase to volume production deployment. We combine a solid technological basis and tried-and-tested Bosch components already in widespread use in volume production with expertise in all technically relevant domains and our own state-of-the-art test benches. This enables us to offer you comprehensive and flexible project management.
Vehicle systems development
Our systems development services at the vehicle level support you from the initial idea to the full-fledged concept – in all relevant domains and taking the interplay of all subsystems into account. We will assist you at all stages, from the initial idea and subsequent requirements management to the simulation and integration of systems and functions. At all stages of the process, we keep a firm eye on the vehicle concept and its requirements. From this we derive all the requirements relating to the various domains (e.g. vehicle dynamics, powertrain, E/E architecture, thermal systems) and their subsystems.
We assist you with the development of hardware, mechanical concepts, and base and application software as well as with function development, integration, the operating strategy, and calibration. We can implement a wide variety of software functions for you in the vehicle control unit, depending on the powertrain concept. Functions can furthermore be updated and enhanced according to your wishes.
Vehicle control unit (VCU)
The vehicle control unit (VCU) enables a common E/E architecture for electrified powertrain systems. It is responsible for various tasks, such as high-/low-voltage coordination, operating strategy, OBD, monitoring, and thermal management. The VCU is suitable for all powertrain topologies for commercial vehicles and passenger cars, from the mild hybrid to the fully electric vehicle.
We assist you with the development of hardware, base and application layer software and its integration. Furthermore functional safety and calibration are also part of our service. We can implement a wide variety of software functions for you in the vehicle control unit, depending on the powertrain concept. Functions can furthermore be updated and enhanced according to your wishes.
Electric powertrains complement today’s wide choice of propulsion systems and offer a range of benefits for different use cases, from zero local emissions to powerful torque when driving off. Together we will analyze your specific requirements and then, based on that, optimize the design and configuration of the electric powertrain system. Bosch Engineering offers you small-batch solutions for custom powertrains based on the entire Bosch technology portfolio. Using Bosch components as a basis, we provide customer-specific hardware and software, mechanical systems for electric motors, electric axles, and power electronics.
Our services include the following:
- Product-specific approval
- Customer-specific function development and subsequent implementation
- Adaptation of performance (e.g. power output, torque, rotational speed) and packaging (e.g. interfaces)
We also support you with concept ideas and prototype engineering with feasibility studies, proof of concept, testing and verification as well as sample engineering and supplying. We validate all engineering steps using extensive simulations; and we develop, compare, and analyze various approaches, topologies, and concepts for you. By using this consistent and integrated systems engineering approach, we achieve the best possible system configuration in terms of costs, efficiency, functionality, installation space, weight, and concept development.
We offer engineering services for custom-designed fuel cell systems, taking all technical aspects into consideration. Starting with the definition and design of the powertrain topology, we support you throughout the development process with the following services and activities:
- Proof of concept
- Simulation study
- Specifying and selecting suitable components
- Defining the test specification and approval criteria for the system as a whole and its subsystems
The fuel-cell control unit features a robust construction, complies with the international standard for functional safety, and has been tried-and-tested in industrial-scale production. A wide range of analog and digital interfaces makes it suitable for various topologies and facilitates flexible integration in a fuel cell system. We use FCCU hardware from Bosch, which we configure and adapt to the individual customer platform software with our calibration services.
High-voltage DC-to-DC converter and charging systems
A reliable high-voltage charging system and a high-voltage DC-to-DC converter that is optimally configured for the vehicle ensure convenient and efficient battery charging and a stable 12 V supply for the vehicle’s electrical system. The high-voltage DC-to-DC converter we supply is based on Bosch technology that has proven its worth in volume production deployment. Our converter combines excellent quality with an appealing benefit-cost ratio. We furthermore offer you a high degree of flexibility, spanning from platform solutions to fully customized software and mechanical systems. Our expertise from numerous customer projects also flows into our charging system development work. Our engineering activities in this area unify the overarching requirements at the vehicle level with the specific requirements in regard to vehicle components. Based on your development requirements, we define the charging function, work out the specifications for the E/E system, and assist you with integration and initial operation.
We furthermore check the charging system’s conformity for the target markets using our hardware-in-the-loop (HiL) high-voltage test bench. We perform all of these activities in close cooperation and consultation with you. This enables us to ensure your electric vehicle can be charged safely, quickly, and with a high level of convenience in any target market in the world. We provide you with a holistic charging solution from a single source: besides developing the charging system, we also implement the appropriate charging functions and communication protocols on a Bosch vehicle control unit (VCU), taking into consideration all your specific needs. This engineering work includes charging communication protocols and their interfaces for AC charging (IEC 61851, SAE J1772; CHAdeMO; GB/T18487) and for DC charging (ISO 15118; GB/T27930; CHAdeMO).
Bosch Engineering can offer you tailored solutions for 48-volt lithium-ion batteries and the battery management system (battery control incl. cell monitoring) for all stages of the engineering process – from the prototype to volume production. We can furthermore provide you with comprehensive support in the development of battery systems for all voltage levels.
In this context, we have extensive experience in using simulation methods to select the right cell technology and in defining mature concepts for battery systems. These include, for example:
- Safety concepts for high-voltage applications
- Designing and sizing battery components