Down to the Details
At Bosch, testing and optimizing components on a computer is increasingly becoming routine. Bosch researchers pay attention to all technical details, such as the stress levels that materials are exposed to, and how reliably products perform their functions.
Each innovative advance makes today’s cars safer, more economical and cleaner. But for the research scientist and the engineer, there’s much more to it: These products are becoming increasingly more complex. Anti-lock brakes, for instance, have added a network of sensors, hydraulics and electronics to the automobile. The Electronic Stability Program (ESP®) is based on ABS technology and integrates even more functions.
Another challenge facing researchers is the dynamic nature of innovation. Whereas ABS took 20 years to achieve 40 percent market penetration, ESP® reached the same level in just half the time. The complexity of product design and the speed of innovation influence all product development at Bosch. And the only way to meet this dual challenge is by applying virtual engineering methods. Bosch researchers are using computers to model and test product designs and their functions.
Rough road. Products can’t be developed in isolation: Components such as ESP® or generators must function perfectly once they have actually been installed in a car. In the past, engineers used to perform road tests to check the vibrations and temperatures to which products were exposed.
But it isn’t possible to drive down a cobbled street when the vehicle only exists on the drawing board. So researchers are now simulating bumpy rides on the computer. With the use of mathematical methods, a generator can be thoroughly vibration-tested in less than a week. Researchers enhance standard simulation software by using sophisticated algorithms to test product functions, and physical experiments are used as reality checks for the computer models. When the computer methods and models have been checked out in Research, they’re released to the engineering departments of the business units.
Down to the tiniest spring. Compression springs rank among the smallest parts of a common-rail diesel direct injection system. After each fuel metering cycle, these little springs push the injector needles back to their starting position. Bosch researchers want to find out exactly how these springs vibrate within their guide channels.
Do they touch the channel wall? Are their movements being damped? Such interactions could affect the quality of the injection - and thus combustion and fuel consumption. Researchers use 3D computer simulation to observe the springs' movements. Even the tiniest spring must last for the lifetime of the whole vehicle.
The tree algorithm. Bosch engineers also imitate nature to optimize their products. The growth of trees is particularly active in places that are exposed to a lot of stress and strain. Engineers apply analogous methods to optimize the geometry of components. To improve the striking mechanism of a rotary hammer, for instance, Bosch researchers applied principles derived from biological evolution. As a result, the removal rate of the tool was increased by 25 percent.
Another challenge facing researchers is the dynamic nature of innovation. Whereas ABS took 20 years to achieve 40 percent market penetration, ESP® reached the same level in just half the time. The complexity of product design and the speed of innovation influence all product development at Bosch. And the only way to meet this dual challenge is by applying virtual engineering methods. Bosch researchers are using computers to model and test product designs and their functions.
Rough road. Products can’t be developed in isolation: Components such as ESP® or generators must function perfectly once they have actually been installed in a car. In the past, engineers used to perform road tests to check the vibrations and temperatures to which products were exposed.
But it isn’t possible to drive down a cobbled street when the vehicle only exists on the drawing board. So researchers are now simulating bumpy rides on the computer. With the use of mathematical methods, a generator can be thoroughly vibration-tested in less than a week. Researchers enhance standard simulation software by using sophisticated algorithms to test product functions, and physical experiments are used as reality checks for the computer models. When the computer methods and models have been checked out in Research, they’re released to the engineering departments of the business units.
Down to the tiniest spring. Compression springs rank among the smallest parts of a common-rail diesel direct injection system. After each fuel metering cycle, these little springs push the injector needles back to their starting position. Bosch researchers want to find out exactly how these springs vibrate within their guide channels.
Do they touch the channel wall? Are their movements being damped? Such interactions could affect the quality of the injection - and thus combustion and fuel consumption. Researchers use 3D computer simulation to observe the springs' movements. Even the tiniest spring must last for the lifetime of the whole vehicle.
The tree algorithm. Bosch engineers also imitate nature to optimize their products. The growth of trees is particularly active in places that are exposed to a lot of stress and strain. Engineers apply analogous methods to optimize the geometry of components. To improve the striking mechanism of a rotary hammer, for instance, Bosch researchers applied principles derived from biological evolution. As a result, the removal rate of the tool was increased by 25 percent.
Researchers are using genetic algorithms to develop more effective and robust rotary hammers.
