International. According to Bosch studies, by 2022 more than half a million construction machines will be produced worldwide in the performance class from 56 to 560 kilowatts.
Worldwide, millions of vehicles reliably perform their work in the mobile, agricultural and construction machinery sectors. However, no matter how diverse their applications, virtually all of these machines run on conventional diesel engines.
At this year's "bauma 2022" trade fair in Munich, Bosch demonstrated how even this vehicle segment can make a greater contribution to climate protection in the future.
"With hydrogen engines and electrification, we can make construction machinery significantly more sustainable," says Thomas Pauer, president of Bosch's Powertrain Solutions division.
"But we also want to achieve further reductions in diesel engine consumption and emissions," he said.
With further growth anticipated for this market in the coming years, Bosch's powertrain division expects to play an equally important role in these developments.
With its solutions, the German company helps car manufacturers around the world comply with current and future legislation on emissions and climate protection.
The hydrogen engine: proven base, sustainable fuel
Hydrogen engines are based on established and proven engine technology that is adapted to ensure a sustainable future. When powered by green hydrogen, these propulsion systems are virtually climate-neutral.
In addition, the powertrain concept represents an effective complement to fuel cell technology, as it requires the same vehicle storage systems and identical infrastructure.
Bosch is working on fuel port and direct injection systems and is already participating in more than 100 technical tests with customers around the world. In addition, the company has already achieved its first volume production project in India.
"Construction machinery is frequently used in stationary high-load applications, and this is the exact environment in which hydrogen engines can shine with their high efficiency and robustness," explains Pauer.
"But the powertrain solution will also be used for agricultural machinery and in long-distance transport."
In addition, the hydrogen engine represents a very promising option in the large engine sector, for example as a powertrain for tippers in the mining industry. This is another area where robustness and reliability combined with a compact design are crucial for efficient operation.
In addition to direct hydrogen injection, Bosch's new AFI-LP (Alternative Fuel Injector – Low Pressure) injector also enables the use of other fuels, such as methanol, for both port and steering fuel. Engine manufacturers can thus benefit from maximum flexibility.
The eLION electrification platform: scalable solution from Bosch Rexroth
Bosch Rexroth offers an electric powertrain solution for mobile construction machinery in the form of eLION. The product platform is specifically designed for the off-road sector and its demanding environmental conditions. It is highly scalable, extremely robust and offers complete functional safety according to ISO 13849.
High-voltage eLION electric motors (up to 850 volts) cover a nominal power range of 20 to 230 kilowatts (with power peaks exceeding 550 kilowatts) and generate nominal torques of up to 1,300 newton meters as well as maximum torques of more than 2,500 newton meters.
Available in four different sizes, they are equally well suited to compact and heavy-duty mobile machinery and can be used for both travel and work functions. Initial pilot projects with customers have been underway since 2021.
Bosch also introduces the SMG180 and SMG220 electric motors, as well as the INVCON 3.3 inverter with its integrated DC/DC converter. These components were developed for use in light commercial vehicles and are also certified for off-highway applications.
Diesel injection systems: a tailor-made solution for every application
Despite these new and sustainable solutions, the diesel engine will remain the most widely used powertrain for construction machinery for some time. Its continued appeal is largely due to its robustness, low operating costs and quick and simple refueling.
Even by 2035, Bosch expects four out of five new construction machines with outputs rated more than 56 kilowatts to roll off the world's production lines with a diesel engine under the hood.
In Munich, the company presents the perfect common-rail injection system (CRS) for each and every application:
The Commercial Vehicle System (CRSN) also serves as the ideal solution for many construction machines and provides injection pressures of up to 2500 bar.
A version designed specifically for industrial applications and off-road operation (CRS OHW) in agricultural and construction machinery impresses with its particular robustness. With an injection pressure of up to 2,000 bar, it offers up to 33 kilowatts per cylinder.
For large engines operating at high and medium speeds, the MCRS modular common-rail system features injection pressures of up to 2200 bar combined with cylinder outputs of up to 500 kilowatts.
With the use of synthetic fuels, all these systems can already make an important contribution to the overall reduction of CO2.
