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Flex fuel systems
Versatile. Economical. Resource-friendly.
clean &economical
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Flex fuel systems forresource-friendly mobility
Flex fuel systems
Tapping into market potential
For many end customers the choice of fuel is the
decisive purchase argument for vehicles with
flex fuel technology. In Brazil for instance, these
vehicles already account for more than 80 per-
cent of the market, while other markets still offer
a great deal of potential for establishing these
systems. And from a macroeconomic perspec-
tive, the use of flex fuel systems means less de-
pendence on crude oil.
Alternative fuel ethanol
Alternative fuels contribute to more economicaland resource-friendlier mobility. Ethanol has
established itself as a fuel particularly with flex
fuel systems; it can be mixed with conventional
gasoline in proportions of between five and
100 percent. Countries such as China are also
using methanol as a fuel.
Until now, ethanol has tended to be distilled
from sugar cane or cereals containing starch.
New technologies are based on the use as
biomass of cellulosic raw materials such as
miscanthus. The use of algae is also being
looked into. So as not to use up arable land,
such algae could be cultivated in offshore parks,
for example.
Flex fuel vehicles come with an injection system that can be operated
with gasoline, a mixture with various ratios of gasoline and ethanol, or
pure ethanol.
End customers thus have a flexible choice of fuel, are less dependent
on having access to one fuel in particular, and can respond directly to
price developments.
Bosch flex fuel systems
provide automakers
with the potential to tap
into new sectors of the
economy.
0
Bosch flex fuel technology for two-wheelers,passenger cars, and light commercial vehicles
Flex fuel system
Our flex fuel system is designed to oper-
ate reliably even from a cold start with a
tank full of pure ethanol. Since ethanol
combustion is problematic at tempera-
tures below 13 , vehicles with the Bosch
flex fuel system are fitted with a small ad-
ditional gasoline tank. On the basis of
sensor data, the control unit can auto-
matically switch to gasoline mode to en-
sure a reliable, comfortable start. Follow-
ing a brief warm-up phase, the system
switches back to ethanol mode.
Flexstart system
Our innovative Flexstart system, which
dispenses with the additional gasoline
tank, provides even more starting com-
fort at cold temperatures. During a cold
start, electrically controlled heating ele-
ments in the fuel rail warm the ethanol to
the required temperature.
Bosch started developing and manufacturing flex fuel technology back in
1986. We comprehensively integrate our expertise and wealth of expe-
rience into the product portfolio for two-wheelers, passenger cars, and
commercial vehicles.
In flex fuel systems, we partner with automakers to continuously develop
the technology.
This improves the ethanol's vaporization
and reduces the amount of fuel required
for injection.
Compared with conventional cold-start
systems, Flexstart reduces CO emissions
by around two percent and HC emissions
by up to 30 percent.
Flex fuel gasoline direct injection
Direct injection offers additional benefits
over gasoline port fuel injection. Air and
fuel are precisely metered, prepared, anddistributed for each combustion cycle.
The result is lower fuel consumption and
reduced emissions, coupled with in-
creased engine power output. Thanks to
consistent further development, our flex
fuel systems can also be used in combi-
nation with gasoline direct injection. Flex fuel injector
Flexstart system
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Further information can be found at
www.bosch-pfi.com
Further information:
www.bosch-flexfuel.com
Automotive competence from a single source:Bosch your partner for flex fuel systems
Comprehensive portfolio and extensive expertise
Our portfolio includes flex fuel systems for two-wheelers, passenger cars, and
light commercial vehicles, as well as for a range of vehicle functions including
fuel supply, fuel injection, air management, ignition, engine management, turbo-
charging, thermal management, exhaust-gas treatment, transmission technology,
and start-stop. Components for the Flexstart system and gasoline direct injection
supplement the product range.
System and network competence
Bosch boasts a holistic understanding of drive systems including knowledge of
the many technical influencing factors, interrelationships, and dependencies of a
flex fuel system. System networking using intelligent software ensures optimum
functionality even with changing fuel-mixture ratios.
Innovation driver and technology leader
We develop flex fuel technology to high-quality, reliable large-scale series pro-duction standards. The Brazilian Ministry of Science and Technology presented
us with the Technological Innovation Finep Award in recognition of this work.
Ensuring quality and reliability
Our portfolio for flex fuel vehicles meets the most stringent technical performance
requirements and offers a high degree of functional safety and reliability even
when used with poor-quality fuels.
Global presence
Bosch has production and development experts on hand around the globe near to
automakers. We are familiar with specific local requirements and help our cus-
tomers tap into new markets.
Long-term partnership
Bosch provides automakers with end-to-end support for their flex fuel activities:
from designing new vehicle concepts, their development and application, through
series production, to vehicle servicing.
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Gasoline SystemsFuel injectors for flex fuel systems
Vehicles with a flex fuel system run on a mixture of
gasoline and bioethanol. The proportion of ethanol
can vary from 5% (E5) to 100% (E100). The Bosch
portfolio encompasses flex fuel systems for port fuel
injection and for direct injection.
Port fuel injection systems prepare the air-fuel mixture
in the intake manifold. The fuel rail distributes the fuel
to the fuel injectors which atomize the fuel into the
intake air flow.
Direct injection systems employ high-pressure injec-
tors. These inject the fuel directly into the combustion
chamber.
Task
With port fuel injection, the fuel injector is responsible
for injecting the fuel into the intake manifold so that
it forms a homogeneous mixture with the intake air;
this mixture is fed into the most favorable area of the
combustion chamber to provide optimum combustion.
The aim is to prevent excessive fuel condensation on
the wall from the intake manifold or intake valve.
The high-pressure injector meters and atomizes the
fuel so that fuel and air are specifically mixed in acertain region of the combustion chamber in order to
obtain the best possible combustion of the mixture.
Function
The fuel injector is a solenoid valve which is used to
control the injection start and duration. The shape
of the fuel spray is determined for each engine by
the position of the injector and the configuration and
number of orifices.
Customer benefits
Reduced emissions
Improved spray preparation
Flexible installation and spray characteristics
for every engine
Savings potential in engine compartment
insulation
Ethanol resistance facilitates worldwide use
Meets requirements for engine downsizing
(advanced spray point)
Additional fuel efficiency and emissions
reduction potential with direct injection
Fuel injectors for flex fuel systems
EV6, HDEV5, EV14
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Robert Bosch GmbH
Gasoline Systems
Postfach 30 02 40
70442 Stuttgart
Germany
www.bosch-automotivetechnology.com
Printed in Germany
292000P14G-C/CCA-201309-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
Variant: fuel injector EV6
The low-noise fuel injector EV6 is available in a large
variety of variants with different lengths and spray
patterns. Linearity is very good with a large Dynamic
Flow Range (DFR) up to 12.
Variant: fuel injector EV14
Low leakage below 1.8 mm3/min is a specific charac-
teristic of the slim and lightweight EV14 injector.
It has been developed as a global injector which is
manufactured locally in all markets worldwide and
it is also suitable for use with flex fuel. The linearity
range is even higher than that of the EV6. The large
variant frame comprises various geometries and
spray patterns.
Variant: high-pressure fuel injector HDEV5The HDEV5 high-pressure fuel injector meters and
atomizes the fuel with high pressure directly into the
combustion chamber. The inward-opening multihole
injector features high variability concerning spray
angle and spray shape. Variable lengths are available
as options for different installation requirements.
Gasoline Systems | Fuel injectors for flex fuel systems
Technical features
EV6
Linearity DFR 12
Droplet size 50130 m (rSMD, reduced
Sauter Mean Diameter)
available
Variants Length, spray pattern
Noise 5153 dB
Fuels Gasoline, ethanol ( E100),
methanol ( M15)
Technical features
EV14
Linearity DFR 13
Leakage 1.8 mm3/min
Droplet size 50130 m (rSMD, reduced
Sauter Mean Diameter)
available
Variants Geometry, spray pattern
Weight ~25 g
Fuels Gasoline, ethanol ( E100),
methanol ( M15)
Technical features
HDEV5
System pressure 20 MPa
Flow rate 25 cm3/s at 10 MPa
Leakage < 2,5 mm3/min at 10 MPa
Fuels Gasoline, ethanol:
all fuel qualities worldwide
Droplet size SMD
(Sauter Mean Diameter) 15 m
Spray form Variable number and position
of spray holes
Injector installation Central or lateral
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Gasoline SystemsFuel rail for flex fuel systems
Task
The fuel rail receives the fuel from the fuel supply mod-
ule and distributes it to the fuel injectors. It is impor-
tant that the fuel has the required pressure at the start
of the injection and that there are no pressure fluctua-
tions between individual injections.
Function
The fuel injectors are mounted on the fuel rail. This
self-damping fuel rail is made out of plastic tailored for
use with ethanol, or out of stainless steel. It features a
highly versatile design and configurations:
Feed line with customer specific connections
Available with our without return line
Available with all variants of the EV14 or EV6/EV6P
in ethanol resistant versions
Vehicles with a flex fuel system run on a mixture of
gasoline and bioethanol. The proportion of ethanol
can vary from 5% (E5) to 100% (E100). The Bosch
portfolio encompasses flex fuel systems for port fuel
injection and for direct injection.
Port fuel injection systems prepare the air-fuel mixture
in the intake manifold. The fuel rail distributes the fuel
to the fuel injectors which atomize the fuel into the
intake air flow.
Direct injection systems employ high-pressure injec-
tors. These inject the fuel directly into the combustion
chamber.
Customer benefits
Simplified logistics, assembly, and handling
Ethanol resistance facilitates worldwide use
Flexible installation/design
Fuel rail for flex fuel systems
Plastic variant
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Robert Bosch GmbH
Gasoline Systems
Postfach 30 02 40
70442 Stuttgart
Germany
www.bosch-automotivetechnology.com
Printed in Germany
292000P14J-C/CCA-201309-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.
Because ethanol is harder to ignite at temperatures
below 20C, Bosch has developed the Flexstart System
to warm the fuel during the starting phase. Flexstart
replaces systems which use gasoline to start the
engine and therefore require an additional tank.
Task
The fuel rail receives the fuel from the fuel-supply mod-
ule and distributes it to the fuel injectors. It is impor-
tant that the fuel has the required pressure at the start
of the injection and that there are no pressure fluctua-
tions between individual injections.
The Flexstart system warms the fuel and ensures a
smooth engine start at low temperatures even with
high-ethanol fuel. Depending on ethanol content and
ambient temperature Flexstart warms the ethanol
using heating elements in the fuel rail controlled by
the engine control unit via the heating control unit.
Function
The fuel injectors are mounted on the fuel rail. This
self-damping fuel rail has been tailored for use with
ethanol. Its specific features are:
Resistant with E100 operation
Determination of the operating mode air or vapor (in
combination with heating element GLP2-FS GLP2-FK
and heating element HCU)
Gasoline Systems | Fuel rail for flex fuel systems
Customer benefits
Reliable engine start with E85/E100 without
an additional gasoline tank
Improved driveability during engine warm-up
Fuel rail for the Flexstart system
Technical features
Fuel rail for the Flexstart system
Operation mode 4- or 3-cylinder operation
Temperature output
between the injectors < 10C
Rate of heating 30C/s
Fuel temperature 70125C (depending on
system pressure)
Variants Plastic or stainless steel
Plastic variant
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Gasoline SystemsElectronic control unitMotronic for flex fuel systems
Function
The electronic control unit for flex fuel systems pro-
cesses input data from sensors located throughout
the drivetrain. It detects which fuel is being used
and adjusts the engine management accordingly. At
higher ethanol content, for instance, the air-fuel ratio
is reduced.
Additionally the control unit can control the Flexstart sys-
tem which warms the fuel and ensures a smooth engine
start at low temperatures even with high-ethanol fuels.
Depending on ethanol content and ambient tempera-
ture the electronic control unit triggers the heating
elements in the fuel rail via the heating control unit.
The electronic control unit variants feature:
uA common platform for gasoline, flex fuel, CNG
and diesel control units
uDiagnostics functions, e.g. for compliance with
emissions legislation
uInfineon 32 bit microcontroller
uStandardized communication interfaces (CAN,
Flexray, SENT, LIN, K-LINE)
uHighly scalable software and hardware, 4-fold
computing power from basic segment to high end
uStandardized formats to support software sharingand global development (AUTOSAR, MSR)
Customer benefits
uOne single, scalable ECU family for different
markets and vehicle segments
uPotential for extended functionality
uFlexible integration of customer software
Vehicles with a flex fuel system run on a mixture of
gasoline and bioethanol which enables up to 40%
lower CO2output than gasoline operation. The propor-
tion of ethanol can vary from 5% (E5) to 100% (E100).
The Bosch portfolio encompasses flex fuel systems for
port fuel injection and for direct injection.
Task
The aim of the electronic control unit is to provide the
required engine torque with minimal fuel consumption
and emissions. It controls mixture formation (air mass,
injected fuel amount, injection timing), ignition and the
exhaust-gas treatment.
Robert Bosch GmbH
Gasoline Systems
Postfach 30 02 40
70442 Stuttgart
Germany
www.bosch-automotivetechnology.com
Printed in Germany
292000P142-C/CCA-201309-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.
Electronic control unit for flex fuel systems
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Gasoline SystemsHeating control unit for theFlexstart system
Function
The heating control unit monitors the heat energy de-
livered in four separate heat circuits. It measures the
supplied temperature and sends this data back to the
engine control unit together with diagnostics informa-
tion.
The heating control unit is characterized by:
uFour individually controlled heating circuits
with 260 W at 12 V each
uPrecise energy control
uIntegrated current sensor
uReverse polarity protection
uFull diagnostics: open/short circuit; switching
elements (FETs)uInternal overtemperature cutoff
uDetermination of the operating mode air or vapor
(in combination with heating element GLP2-FS)
Customer benefits
uReliable engine start with E85/E100 even at
low ambient temperature
uImproved driveability during engine warm-up
Vehicles with a flex fuel system run on a mixture of
gasoline and bioethanol. The proportion of ethanol can
vary from 5% (E5) to 100% (E100). The Bosch portfo-
lio encompasses flex fuel systems for port fuel injec-
tion and for direct injection.
Because ethanol is harder to ignite at temperatures
below 20C, Bosch has developed the Flexstart system
to warm the fuel during the starting phase. Flexstart
replaces systems which use gasoline to start the
engine and therefore require an additional tank.
Task
The heating control unit monitors the heating of the
fuel in order to ensure a fast, comfortable and clean
engine start. Flexstart replaces systems which use
gasoline to start the engine and therefore require an
additional tank.
Robert Bosch GmbH
Gasoline Systems
Postfach 30 02 40
70442 Stuttgart
Germany
www.bosch-automotivetechnology.com
Printed in Germany
292000P14N-C/CCA-201309-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.
Heating control unit for the Flexstart system
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Gasoline SystemsHeating element for theFlexstart system
Function
The heating element dissipates heat to the fuel within
the fuel rail, so the fuel has the right temperature
when it is injected. The material of the heating element
has been specifically selected for operation with high
surface temperature, while it is immersed in the fuel.
Its rated output is 260 W at 12 V.
The heating element is characterized by:
uResistance against E100
uDetermination of the operating mode air or vapor
(in combination with the heating control unit HCU)
Customer benefits
uReliable engine start with E85/E100
even at low ambient temperature
uImproved driveability during engine warm-up
Vehicles with a flex fuel system run on a mixture of
gasoline and bioethanol. The proportion of ethanol can
vary from 5% (E5) to 100% (E100). The Bosch portfo-
lio encompasses flex fuel systems for port fuel injec-
tion and for direct injection.
Because ethanol is harder to ignite at temperatures
below 20C, Bosch has developed the Flexstart system
to warm the fuel during the starting phase. Flexstart
replaces systems which use gasoline to start the
engine and therefore require an additional tank.
Task
The heating element is there to ensure a comfortable
and clean engine start when using high-ethanol fuels at
temperatures below 20C. Flexstart replaces systems
which use gasoline to start the engine and therefore
require an additional tank.
Robert Bosch GmbH
Gasoline Systems
Postfach 30 02 40
70442 Stuttgart
Germany
www.bosch-automotivetechnology.com
Printed in Germany
292000P14L-C/CCA-201309-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
Heating element for the Flexstart system
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Robert Bosch GmbH
Gasoline Systems
Postfach 30 02 40
70442 Stuttgart
Germany
www.bosch-flexfuel.com
Printed in Germany
2 920 00P 0ZU-C/CCA-201304-En
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