50 million injection valves and 10 million high-pressure pumps manufactured at Bosch

Rapid market growth continues

• Gasoline direct injection is key for economical engines
• Up to 15 percent lower fuel consumption and CO2 emissions
• Global manufacturing network

Gasoline direct injection systems are continuing to enjoy rapid market growth. Thanks to this, the Bosch Gasoline Systems division is celebrating a production milestone in November 2012: 50 million gasoline injection valves from the HDEV5 series and 10 million high-pressure pumps from the HDP line have been manufactured. Only last year, the 25 millionth injection valve and the 5 millionth high-pressure pump rolled off the line in the Bosch global manufacturing network. Within a year, then, the total number manufactured has doubled. The HDP went into series production in 2006 and initially featured in GM’s Ecotec engines. The HDEV5 had its premiere that same year in the PSA/BMW Prince engine.

Bosch: pioneer in gasoline direct injection

The supplier of technology and services is regarded as a pioneer in the area of gasoline direct injection. Bosch launched this technology in 1951, initially for the two-stroke engine of the compact Gutbrod Superior car. Three years later, gasoline direct injection for four-stroke engines debuted in the legendary gull-wing Mercedes-Benz 300 SL. This paved the way for the development of passenger-car gasoline engines that combined higher performance with lower fuel consumption and emissions. When gasoline direct injection is used in combination with turbocharging and electronic engine management, it results in an approximately 15 percent reduction in fuel consumption and CO2 emissions, and achieves this without sacrificing torque or performance.

The combination of turbocharging and gasoline direct injection also permits downsizing – that is, engines with smaller displacements which consume less fuel and emit less CO2. Since ever more automakers are opting for downsizing, the international market for gasoline direct injection systems is steadily growing. “We estimate that by 2015, the share of gasoline direct injection will triple to 18 percent of all vehicles manufactured worldwide,” says Dr. Rolf Bulander, the president of the Bosch Gasoline Systems division.

Injection pressures up to 200 bar

If mixture formation is homogeneous, the HDEV5 high-pressure injection valve makes a major contribution to optimum, and thus fuel efficient, combustion. Up to seven individually positioned injection holes enable the spray pattern to be flexibly adapted to different engines. Moreover, the high-pressure injection valve and the high-pressure pump are designed for system pressures of up to 200 bar. The HDP5 high-pressure pump is characterized by its compact dimensions and its light, 750-gram weight. Thanks to the use of stainless steel, the current components of the gasoline direct injection system are highly resistant and can handle fuels such as ethanol, which makes them suitable for worldwide use. Bosch currently produces high-pressure pumps and injection valves at its lead plants in Bamberg and Nuremberg (Germany), as well as in Bursa (Turkey), Wuxi (China), Charleston (U.S.), and Korea.