Mastering electrification with virtual product engineering

An electric drivetrain should be powerful, compact, silent, and cost efficient – a tall order. Virtual product engineering is suitable for such a challenge because it creates sophisticated mathematical models, runs simulations on high performance computers, and employs optimization algorithms. Product designers can then evaluate different combinations of compromises – using a tool called multi-objective optimization – to find the best solution.

We teamed up with business units and world-leading university institutes to design a multi-objective optimization environment for electric drivetrains. They succeeded reducing costs by 20 percent while increasing performance by 30 percent, even for mature products. They did it by adopting state-of-the-art modeling, simulation, and optimization technologies, including commercial tools and in-house developments.

Bosch is spreading the use of these tools throughout its electrification business. Superior products are designed to reach their physical limits, and customers’ needs are central to design choices. Mass production is modeled and optimized before it even begins. A dedicated team leverages Bosch’s international network to maintain and support these powerful tools.

Our researchers are constantly refining these methods, for example by employing free shape and topology optimization in connection with adjoint methods and artificial intelligence. We want to pair human creativity with computer-powered inspiration to arrive at product designs that are not just surprising, but aesthetically compelling.