Diesel SystemsHybrid drive systems for the off-highway segment

Technological development in the off-highway segment is driven by the will to increase productivity and lower operating cost. With their increasing use in the automotive segment electrified drive topologies are also becoming cost-efficient when applied to increase the productivity of working machines.

Potential applications In the off-highway segment there are multiple applica-tions for hybrid drives: from electrification of subsys-tems and power take-offs or power assistance through to downsizing and downspeeding of the combustion engine by powertrain electrification. Functions such as start/stop or energy recuperation can be implemented. The numerous conditions of service of working machines result in a wide range of different require-ments in terms of desired functionality and packaging.

With its wide range of series-tested electric motors and power electronics Bosch is able to deliver the appropriate response to these manifold requirements. Since 2010, these products have been mainly used in hybrid and electric drives of cars and light commercial vehicles. Building upon this extensive experience in development and manufacturing Bosch is systemati-cally expanding the scope of applications. The result is a modular concept which provides for a comprehensive market coverage of drive variants of light-duty, medium-duty and heavy-duty applications in long-haul and distributor vehicles and busses. Hybrid drives suitable for off-highway applications can be configured as well.

Customer benefits: machine manufacturers Downsizing and downspeeding of the

combustion engines Highest system reliability No additional maintenance required for

electric machine and power electronics Series-tested, mature development and

manufacturing processes Possibility of further efficiency increases

by electrification of subsystems and power take-offs

Customer benefits: vehicle operators Reduction of fuel consumption Increase of productivity Start/stop function possible Electrification of power take-offs and implements Worldwide Bosch Service Network

Electric hybrid vehicle

25

3

4

3

Signal wiringHigh voltage supply

Electric machine (Integrated Motor Generator, IMG)

High voltage battery Inverter (optional with DC/DC converter)

Electric Machine (Separated Motor Generator, SMG)

Electronic control unit

3

4

5

2

11

Robert Bosch GmbHDiesel Systems

Postfach 30 02 2070442 StuttgartGermany diesel@bosch.com

www.future-with-diesel.com Printed in Germany292000P0ZS-C/CCA-201303-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

Hybrid system for off-highway applications The electric drives and the inverters are the core components of the Bosch hybrid system. The ssys-tem’s flexibility allows it to be used under most diverse operating con ditions. The system’s configuration derived from a selection of different control strategies and degrees of hybridi zation is always geared towards the specific conditions of use.

FunctionThe electric machine is controlled by the inverter which converts the direct current from the battery into a three-phase alternating current and sets the required torque and speed of the electric machine. If requested by the customer, the control unit can also take over hybrid system control functions. This ensures an optimal distribution of the power output between the combustion engine and the electric machine.

A central control unit, e.g. a vehicle management computer, can be used to regulate the overall energy management to ensure that the energy flows of various subsystems (energy recuperation, cooling system, power take-offs, etc.) are coordinated in an optimum manner.

OutlookIn future, hybrid drives will not remain limited to cars; to an increasing extent they will also be applied in commercial long-haul and distributor vehicles as well as in the off-highway segment. This will result in a significant increase in the efficiency of these vehicles’ and machines’ drive systems.

Bosch is developing and manufacturing future-oriented electrified drive solutions for all segments from light-duty, medium-duty and heavy-duty all the way to off-highway applications.

Diesel Systems | Hybrid drive systems for the off-highway segment

Technical features: electric machineMax. power ≤ 60 s 40 – 120 kW

Max. continuous power 20 – 65 kW

Max. torque ≤ 60 s 400 – 1,000 Nm

Transmission interface SAE1, SAE2 or LD

Cooling Water or oil

Applications HD, MD, LD, off-highway

Scope of supply Complete electric machine or active parts

Bosch: Automotive competence from a single source

Comprehensive range of services and know-how

System and network competence Innovator and technology leader

Warrantor for quality and dependability

Worldwide presence Universal partner

Technical features: inverterMax. power 40–120 kW

Max. current 480 Arms (≤ 10 s)

400 Arms (≤ 60 s)

Continuous current 240 Arms

Supply voltage 12 V, 24 V

Max. cooling temperature 65°C (without derating)

Technical features: hybrid systemInput voltage 180 – 450 Vdc with derating > 430 Vdc

Lifetime 15,000 h

1

2

System components and applications

Electric machine (Integrated Motor Generator, IMG)

Inverter

1 2