Bhumanyu Singh’s Capstone Research Project Promises Cleaner Cars and Air with Bosch and Boysen’s Innovative RCH System
Bhumanyu Singh embraced a challenge that promises to make us all breathe a little easier.

As part of his capstone project in summer 2024, Singh was tasked with refining the Rapid Catalyst Heating (RCH) system — a pioneering Bosch and Boysen innovation — for gasoline-fueled engines. Under the tutelage of U-M Mechanical Engineering Professor Dr. Margaret Wooldridge, Singh faced the looming shadow of stringent CARB LEV-IV and EPA Tier-4 regulations while diving deep into the nuanced world of cold-start emissions, armed with the legacy of Michigan engineering, People First brand, and a vision for a greener, cleaner future.
The capstone project’s objective was to enhance detection and diagnosis of pressure-based combustion within the RCH system, ensuring efficient catalyst heating and significant emission reductions.
“Automakers face increasing pressure to reduce tailpipe emissions,” Singh said. “This RCH system is engineered to deliver high thermal power output and has proven significant improvement in catalyst performance. Benchmarking initiatives place this system at the forefront of current market offerings, outshining traditional methods reliant primarily on precious metal loading for catalyst efficacy, and modern engine controls, or electric catalyst heaters.”
Bringing Bosch and Boysen’s Technology to New Heights
At Bosch’s Farmington Hills, Michigan, facility, Singh studied the intricacies of cold-start emissions, where catalysts took their time to heat up, allowing harmful gases to slip through unmitigated. He harnessed the power of the RCH system to quickly achieve the required temperatures for optimal emissions reduction. His task was twofold: First, to calibrate the RCH’s combustion system for robust performance, particularly during those crucial cold starts; and second, to refine the pressure-based combustion detection function embedded within the system — a detection function that stood as a sentry, ensuring the catalyst never overstepped into dangerous thermal territories.
Singh meticulously bench tested the RCH system, striving to achieve a lambda value of 1 within mere seconds of start-up, a delicate dance of air and fuel. Misfires plagued his early attempts, but undeterred, he iterated patiently. His breakthrough came with the introduction of a back-pressure valve to the apparatus, which replicated the on-vehicle conditions more faithfully. The misfires abated and clean burns ensued.
“This is a crucial system function that ensures system efficiency and safety, allowing the catalyst to quickly light-off while protecting from reaching unsafe temperatures,” he said. “Along with component diagnostics, function diagnostics like the pressure-based combustion detection will ensure that the RCH system is always operating within the set parameters.”
Reduced Pollution and Cost Savings
Next came the task of perfecting the pressure-based combustion detection, a nuanced endeavor involving different sensors and their placements. Here, the absolute pressure sensor displayed its prowess — detecting combustion events with superior clarity compared to its HFM8 counterpart. With placement, calibration, and the Göertzel algorithm tools, Singh found the downstream placement of sensors reduced noise and improved detection fidelity, even under the artificial duress of induced misfires.
With the infernal mechanics tamed, Singh’s recommendations were clear: 1. Adopt the absolute pressure sensor for its reliability; 2. Test varied placements to further optimize the setup; and 3. Integrate an On-Board Diagnostic (OBD) system within the BuCU for seamless and robust compliance with regulatory demands.
The impact of his work was far-reaching: Financial savings for manufacturers are expected because of reduced reliance on precious metals in catalysts, increased market positioning for Bosch, and, crucially, a notable reduction in environmental pollution. Cleaner air, healthier lives — a tangible benefit for all.
Singh’s capstone journey from theory to practice reveals the alchemical marriage of engineering insight and problem-solving tenacity, and a path toward a cleaner, greener automotive future.
“The proposed adjustments are designed to seamlessly fit into existing vehicle architectures, thus ensuring a smooth transition to this more environmentally friendly technology,” he said. “The RCH system enhancement will constitute a pivotal improvement in Bosch’s ICE vehicle optimization initiatives, staying ahead of regulatory demands and solidifying the company’s reputation as a leader in sustainable automotive technology.”