The manufacture of Tata Nano at Singur in West Bengal may attract the attention
of the world but the car that made news at the Auto Expo 2008 in January this
year reflects a new side of the Indian OE and tier suppliers. Bosch, which set
up its manufacturing operations in India in 1953, has played a vital role in the
successful creation of Tata Nano. Bosch developed the Value Motronic multi-point
fuel injection system and two cylinder common-rail diesel injection system,
which are capable of meeting the emission norms as good as the costly cars on
the market and cost a good deal less.
Stressing on the presence of six Bosch companies in India, V K Vishwanathan,
managing director of Bosch India, announces that his company is engaged in the
development of low price systems: "Gasoline and common-rail systems,
braking systems, starters and generators, glow plugs and more".
Vishwanathan adds, "Bosch has the first mover advantage and with six group
companies in India, and is growing in a very big way." Touching upon the
Euro 46.3 billion turnover of Robert Bosch (global) and the acquisition of ersol
Solar Energy GmbH, which specialises in photovolt systems, Vishwanathan
expresses that his company is committed towards long term growth and
leadership.
 In
the year 2007, Bosch in India achieved a turnover of Rs 5708 crores and employed
17,780 people. An ECU unit was set up a few months ago and a join venture
between Bosch (Netherland B V) and Igarashi Motors India for the manufacture of
electric motors. The six Bosch companies in India thus include Bosch Limited,
Bosch Rexroth, Bosch Chassis Systems, and Robert Bosch Engineering and Business
Solutions, apart from the two companies mentioned earlier. In the auto sector
business, Bosch India at its technical centre in Adugodi, Bangalore, has
invested close to Rs 20 crores to set up new test beds for engines that meet the
Euro IV and Euro V emission standards; and three new AC dynos - from 120 kW/225
NM to 330 kW/1400 Nm, accredited by NABL.
Stressing upon Bosch India's role in diesel engine management systems, Dr
Manfred Duernholz, joint managing director of Bosch India, says, "Fuel
consumption is even today the main topic of diesel engine; no other engine is as
thermally efficient. Fuel consumption is also linked with emissions.
Expectations in India also include performance and value for money."
Announcing that India is today a land of opportunities, Dr Duernholz adds:
"There are vehicles that are exported to developed markets. There are
hybrids. There are single cylinder and two-cylinder engines that need to be as
efficient as any in the world. This puts the focus on low cost common-rail
systems." Bosch developed the two-cylinder common-rail system of Nano in
India. There's a special injector, ECU and the pump, quips Dr Duernholz. The
system in the Nano is not a low-end system, and has to meet one of the most
stringent emissions norms coming up in the near future. The highlight of the
system is the PF pump that can reach 1450 bar pressure and weighs just 0.43 kg.
The injector of the Nano is made at Nashik and the quality standards are on par
with those in Europe. Some functionality changes were done but none comprised on
quality. Bosch has invested to the tune of Rs 500 crores for the injectors
manufacturing facility, which is of course not exclusive to the Nano.
 Emphasising
on focusing on products tailored to the Indian market, Dr Duernholz avers,
"There is a need for infrastructure for driving and application; need for
knowledge to develop ingenious solutions and invest in R&D." Then there
are other concerns. "Diesel is said to be dirty and a fuel with high
emissions. Raw emissions include 75.2 per cent nitrogen, 2.6 per cent of H2O,
7.1 per cent of CO2, 15 of O2. Harmful emissions form the remaining 0.09 per
cent, which include CO, NO2, HC, sulphate, Aldehyde and solids," explains
Duernholz. The year 2010 will see emphasis on common-rail systems to meet Euro
IV and Euro V emissions and would need combustion optimisation, air system
upgradation, turbo-charger optimisation, EGR, etc. "We are doing it the
Indian way by taking mechanical systems and developing systems that meet
emissions. The end customer has a choice to choose between mechanical, cost
effective systems or high-tech solution," expresses Dr Manfred Duernholz.
"We have to look at interdisciplinary system approach. We have to be
careful to not make the diesel engine expensive."
As for the petrol engine systems, Manjunath PR, head of engineering and
applications for gasoline systems at Bosch India, says, "Market driver in
India is miles per (fuel) cost." Manjunath, who played a key role in the
development of gasoline injection system for the petrol Nano, adds, "Value
Motronic for small cars includes cost effective ECU unit, smart use of sensors,
elimination of double use and development of value components like ignition coil
and throttle position sensors. We support OEs to meet market and customer
requirements."
In the case of low-cost, smart solutions, Bosch engineers in India included
system requirements and sensor requirements. They integrated single components
into modules, developed intelligent sensors, reduced data rate to ECU and
enhanced the signal quality. The engineers in India are also working on Direct
Gasoline Injection (GDI) systems with a focus on fuel economy and CO2 reduction.
"Our vision for the future includes port fuel injectors (PFI), GDI,
start/stop systems, lean start-turbo-VVT (variable valve train), which makes the
least pollution and most efficient set-up. We are looking at HEV parallel PFI.
We are also looking at CNG+PFI, turbo+VVT."
 Bosch
has developed start-stop systems, one of which could be found on the Scorpio and
Bolero. While the Starters/Generators business division was instrumental in
developing a smart D60 starter for Nano, which is 30 per cent more powerful and
costs 25 per cent less according to Narayan C H, Head - Research &
Development, Starters Generators Division, Bosch India, the start-stop systems
saves 8-15 per cent fuel and reduces CO2. "It is a ECU controlled system
that has a start-stop co-ordinator and controller," Narayan explains.
"The controller is fed with signals from various co-ordinators."
Interestingly, the engine of the vehicle fitted with start-stop system shuts
down if it is stationary for 10 seconds with the gearshift in neutral. This is
down with due warning via a flashing LED on the dashboard. On depressing the
clutch the engine fires to life.
The necessity to shift into neutral was arrived for reasons of safety. Safety of
an automobile is one area the Pune-based Bosch Chassis Systems is working upon.
With the production of ABS and ESP systems to commence in 2009, the division is
engaged in the development of various, advanced braking systems and accredits.
"India has a high fatality risk. Celebrating 38 years of ABS, we are
looking at ABS, TCS and ESP as active safety solutions including India,"
says Andreas Berg, business head, active and passive safety, Bosch Chassis
Systems India. Emphasising on ABS and ESP being offered as yet another feature
rather than limiting it to the top-end version, Andreas explains that skidding
is a major reason for several fatal accidents.
 R
K Shenoy, vice president, Robert Bosch Engineering and Business Solutions, and
his team based out of Bangalore and Coimbatore aid various Bosch teams to
optimise software platforms. The largest development centre outside of Germany,
the business areas of Robert Bosch Engineering and Business Solutions include
embedded software and primarily automotive. "We work on software for
clusters, navigation systems and complete production divisions like electronics,
software, mechatronics, EMI/EMC cluster, validation, PCD layout, reliability and
multimedia," remarks Shenoy.
Shenoy and his team worked on the Nano for diesel and petrol engine management.
"Use of electronics in auto is going up rapidly. By 2015 we expect 60 per
cent electronic content in auto and an increased use of mechatronic systems.  Individualisation
will be dictated by software differentiation and hardware will be more or less
the same." Shenoy touches upon the increased use of CAN Bus systems even as
FlexRay and MOST will take precedence. He quips that the rate of data exchange
will increase as features like CAPS become prominent. Interestingly, Shenoy's
business division has developed the Autosar (Automatic Open System architecture)
initiative and Cubas software platform, which will be aimed at low cost
applications and future development respectively.
The pace of new developments at Bosch and especially those that involve India,
reflect the changes that are affecting the Indian subcontinental region, in the
automotive segment to be precise. Despite the general slow down in the economy,
the auto sector in India seems upbeat about strong growth. The frequent launches
of new models and upgrades are an indication of this mood, but when it comes to
critical developments that could change the landscape for ever, India seems to
be the place. It is not without a reason that Dr Duernholz says that India today
is a land of opportunities.
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