Bosch Celebrates 75 Years of Diesel Injection

Sep. 01, 2002 By The Bowtie

FARMINGTON HILLS, Mich., Sept. 19 -- In 1927, Bosch revolutionized the diesel industry with the world's first large-scale production of diesel injection pumps and injectors. This technology allowed engine manufacturers to economically produce small, fast-turning diesel engines for trucks, buses and eventually automobiles.

When first introduced, diesel powerplants were expensive, inefficient and produced in small numbers for large, stationary power or ship engines. In 1921, Bosch began experimenting with diesel injection systems and by 1924 was able to test prototype diesel injection pumps. In March 1927, Bosch provided experimental injection pumps to engine manufacturers and in November 1927, Bosch began large-scale production for M.A.N., a German company that utilized the technology on its trucks. This marked the beginning of diesel's widespread use.

In 1936, injection pumps were developed for diesel-powered automobiles and in 1962, the first distributor injection pump was launched. By 1989 Bosch fitted the Audi 100 with the first direct injection system and in the 1990s, Bosch introduced high-pressure direct injection, the radial-piston pump (VP44), Common Rail and the unit injector system (UIS), all of which played an important role in the advancement of diesel.

Today, the compression ignition engine is widely accepted in Western Europe with nearly 36 percent of newly registered cars sporting diesel engines. The technology also is gaining popularity in the United States. Research shows that roughly one third of Americans would consider purchasing a clean diesel, if given the option.

"I am absolutely convinced that diesels are the best solution for the United States' energy debate," said Kurt Liedtke, president, chairman and chief executive officer, Robert Bosch Corporation. "The technology exists, fuel economy improvements are for real, emission levels are in check, the economy is ripe, consumers want them, and it's an answer that's ready today."

Bosch designs and produces precision automotive components and systems sold to vehicle and powertrain manufacturers worldwide. These include systems and components for gasoline and diesel injection, airbag components, ABS and conventional braking systems, telematics, as well as small motors, electrical and electronic equipment.

Robert Bosch Corporation, the wholly owned subsidiary of Robert Bosch GmbH, headquartered in Stuttgart, Germany, is responsible for North American operations.

75 Years of Bosch Diesel Systems: Milestone Timeline and Technology Highlights

1921: First experiments with fuel injection using modified Bosch oil pumps.

1922: Start of development of diesel injection equipment.

1923: First prototypes of diesel injection pumps.

1927: Clearance for the world´s first large-scale production of injection pumps and injectors.

1934: 100,000th diesel injection pump produced.

1936: Launch of the world´s first series-production of diesel injection equipment for passenger cars.

1950: 1,000,000th diesel injection pump produced.

1962: Launch of first distributor injection pump.

1986: Launch of the world´s first Electronic Diesel Control (EDC).

1989: Direct injection for passenger cars with the VP34 electronically-controlled distributor injection pump; first installed in Audi 100 TDI.

1993: Start of volume production of the electronically-controlled in-line injection pump with control of injection timing and fuel quantity.

1994: Start of production of the UIS Unit Injector System for commercial vehicles.

1995: Start of volume production of the world´s first Unit Pump System (UPS) for commercial vehicles.

1996: Start of volume production of VP44 high-pressure distributor injection pump (radial piston distributor injection pump).

1997: Common Rail System (CRS) for automobiles launched – a world first.

1998: Delivery of first Unit Injector System (UIS) in the world for passenger cars.

1999: Start of production of Common Rail System (CRS) for commercial vehicles.

2001: Bosch produced over 5 million direct injection systems for diesel-powered passenger cars; in total, the company has produced more than 12 million high-pressure injection systems for automobiles.

Injection pressure: The injection pressure can be as much as 2050 bar. This is equivalent to the force that the weight of a medium-sized family car would exert on an area the size of a finger-nail.

Injection speed: Fuel passes through the injector jets at speeds of nearly 1500 miles per hour – as fast as the top speed of a jet plane.

Injection duration: Fuel is injected into the combustion chamber in less than 1.5 milliseconds (one and a half thousandths of a second) – about as long as a camera flash.

Injection quantity: The smallest quantity of fuel injected is one cubic millimeter – about the same volume as the head of a pin. The largest injection quantity at the moment for automobile diesel engines is around 70 cubic millimeters.

Injection frequency: If the camshaft of a six-cylinder engine is turning at 4500 rpm, the injection system has to control and deliver 225 injection cycles per second.

Engine size: The current size of passenger car diesel engines ranges from a three-cylinder engine with an 800cc cylinder capacity and a power output of 33 kilowatts to a four-liter eight-cylinder engine producing more than 180 kilowatts. Volkswagen will be supplying a five-liter, 10-cylinder engine developing 230 kilowatts.

Fuel consumption: On a demonstration drive, a Volkswagen 1-liter diesel-powered car used only 0.89 liters of fuel in covering 100 kilometers – making it probably the most fuel-efficient car in the world. Bosch’s high-pressure fuel injection system was one of the main factors behind the prototype’s extremely low fuel consumption. Production record-breakers in fuel economy include the Volkswagen Lupo 3L TDI and the Audi A2 3L 1.2 TDI with standard consumption figures of 3 liters of fuel per 100 kilometers. Their high-pressure diesel injection systems are also supplied by Bosch.

The market for diesel engines: In 2001, nearly 36% of newly registered cars in Western Europe had diesel engines. Austria leads the league table of registrations of diesel-powered cars with 66%, followed by Belgium with 63% and Luxemburg with 58%. Germany, with 34.6% in 2001, was in the middle of the league table. By way of comparison: in 1996, diesel-powered cars made up only 15% of the new car registrations in Germany.

Diesel engines in motor sport: In 1998, for the very first time in the history of the legendary 24-hour race at the Nuerburgring, a diesel-powered car was the overall winner – the BMW works team 320d, fitted with modern high-pressure diesel injection technology from Bosch.

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