Systematic simulations

Consumers can expect the highest quality and durability standards from Bosch products. Bosch professional power tools, for instance, are optimized until they can withstand a fall from a great height.

How to create maximum quality – the virtual impact test
What exactly happens when a cordless powerdriver falls several meters on concrete, tiles or similar hard surfaces? And how can this be determined quickly, without having to keep testing machines in impact tests?

Computer simulation is the answer. First, a 3D model of the device is created in the computer. Bosch developers then subject the casing to virtual forces corresponding to those in a real impact. The simulation shows exactly where the maximum stress is generated.

Detailed analysis
Based on a process called Finite Element Method (or FEM), properties of the materials and physical conditions can be precisely simulated in the computer. This means that many different construction models can already be calculated very quickly at the development stage.

The Finite Element Method is used to detect sensitive areas as in a cordless powerdriver. They can then be modified – by targeted reinforcement or by using a different material. The modifications are tested straight away until the right solution for optimal durability is finally found.

This intensive development work pays off: The powerdriver from Bosch still works after falling from a height of several meters. And Bosch provides a three year guarantee on power tools for professional work.

Pioneering development methods

The Finite Element method is just one of several processes for studying and optimizing designs on the computer at the draft stage, before real prototypes are built.

Everything in motion
Multi-body system simulation is used for products with moving and turning parts. This simulation technology was used, e.g. in developing a new generation of generators. Researchers at Bosch focused on unwanted vibrations, which could impair smooth operation and durability.

Perfect order
Another simulation method is called CAO – Computer Aided Optimization. This process can determine the ideal arrangement for a set of components – e.g. for starter bearings or a gas pedal module.

Better all the time
As the requirements placed on materials, constructions and machines and system complexity grow, simulation methods also need to be upgraded and reassessed. Simulation experts in Bosch laboratories are researching new processes and technologies to ensure the perfect quality of future Bosch products from the outset.