Bosch e-GoKart PowerTrain Young Star Manual Download Page 53

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Wiring Harness instruction / Build up chassis | 6

Bosch Motorsport

e-GoKart_Powertrain__Young_Star__Manual

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Pin 1: yellow

Pin 2: brown

Illustration 58:

How to solder the wiring on the Reverse Switch

Please solder the open end wiring to the pins of the switch.

– Brown: Switch

– Yellow: Switch

Illustration 59:

Please fix the wiring on the steering wheel.

Illustration 60:

Fix the wiring under the metal sheet.

Summary of Contents for e-GoKart PowerTrain Young Star

Page 1: ...e GoKart Powertrain Young Star Manual 2 13 03 2019 ...

Page 2: ... 4 1 Vehicle Control Unit VCU MS 40 16 4 2 Energy Storages ES 5 2 4 16 4 3 Power Unit PU 5 10 19 4 4 DC DC Converter 22 4 5 Charger Energy Storage CH 5 1 2 23 4 6 Display Unit DDU 18 29 5 Overall Integration Requirements of e GoKart System Components into the Superior Vehicle Context 31 5 1 Electrical Integration 31 5 2 Mechanical Integration 31 5 3 Component Integration Requirements 32 6 Wiring H...

Page 3: ... accessories Operation of the Powertrain e GoKart is only certified with the combinations and ac cessories that are specified in this manual The use of variant combinations accessories and other devices outside the scope of this manual is only permitted when they have been determined to be compliant from a performance and safety standpoint by a repres entative from Bosch Motorsport NOTICE For prof...

Page 4: ...acturer are real ized by the vehicle manufacturer This aims especially to the compliance with the bot tom up requirements BOSCH MOTORSPORT BOSCH Engineering GmbH as the manufac turer supplier of BOSCH MOTORSPORT E GoKart System described in this document 2 1 Conditions of Use 2 1 1 Terms and Specifications for Product Liability Please be especially aware of all conditions states in the following s...

Page 5: ...ORT Related expenses have to be compensated by the CUSTOMER Deliverables shall not be stored in humid moist conditions especially in case of oversea transportation and shall never be exposed to extreme heat or fire nor corrosive sub stances This applies to installed and uninstalled units as well as packed and unpacked units If components are strongly subjected to water e g due to transportation ap...

Page 6: ...rature radiation If necessary the CUSTOMER shall install thermal insulation measures in order to avoid damage of adjacent components 2 1 4 Environmental Conditions The BOSCH MOTORSPORT e GoKart System is designed for an operation in typical European climate zones with an ambient temperature of 5 to 35 C Operation with re duced performance is possible for 8 to 40 C ambient temperature Performance r...

Page 7: ...plicable have to be checked AC cable from AC plug to Charger Energy Storage CH 5 1 2 has to be checked If the cable has any damages it has to be replaced It is not allowed to use a vehicle with defect AC cable All movable cables have to be checked e g cables to the Power Unit PU 5 10 if the Power Unit PU 5 10 is integrated in rear swinging fork If the isolation is defect the cable has to be exchan...

Page 8: ...tandards The e GoKart System is a platform for easy scalability over different vehicle classes and types 3 1 System Description The BOSCH MOTORSPORT e GoKart System perfectly harmonizes components for an easy and fast electrification and a unique driving experience Therefore several compon ents are connected in a system context to form a high performance system to meet the needs of the CUSTOMER Th...

Page 9: ...48 V traction net voltage range Voltage Effect 32 5 V System will shut off for the current driving cycle Driver has to turn the key terminal 15 to restart the system System should be charged 32 5 to 42 25 V System will remain active but will derate driving torque 42 25 to 52 V System returns automatically to full func tionality when voltage is 36 V 52 to 54 V Normal operating range 3 2 2 12 V Batt...

Page 10: ...oKart System When switching the drive modes during driving torque will be ramped up or down re spectively so that no sudden torque variations may occur 3 3 3 Speed Limiter In order to make the driving experience for the driver as comfortable as possible the BOSCH MOTORSPORT e GoKart System implements a speed limiting function that en ables a smooth transition towards top speed 3 3 4 Offboard Charg...

Page 11: ...he maximum power is automatically limited to an allowed level This temporary limitation is called derating and is generally caused by high temperature of the electric machine or any of the available Energy Storages ES 5 2 4 Derating ensures component protection without having a sudden loss of operation The power limitation is dynamically based on system conditions and is reversible i e the system ...

Page 12: ...l system components via one single system interface with a defined tester interface infra structure Software updates will be provided by BOSCH MOTORSPORT if necessary It is not allowed to update the software of the BOSCH MOTORSPORT e GoKart System by the CUSTOMER or any other third party without explicit authorization by BOSCH MO TORSPORT 3 3 10 Deep Discharge Protection Operation of the BOSCH MOT...

Page 13: ... wir ing harness will damage the Energy Storages ES 5 2 4 The Energy Storage ES 5 2 4 in ternal fuse will activate and cannot be replaced For the electrical integration of the BOSCH MOTORSPORT e GoKart System require ments from Charger Energy Storage CH 5 1 2 23 shall be considered 3 4 2 Powertrain Integration The BOSCH MOTORSPORT e GoKart can be connected to the powertrain of the vehicle in sever...

Page 14: ...en Vehicle active Power Unit PU 5 10 locked 3 Driving Screen Power Unit PU 5 10 enabled 4 Crawl Screen Indication of driving direction for parking 5 Menu Screen Adjustable vehicle settings The Welcome screen is shown first at key on terminal 15 After system start up the screen changes automatically to Start Screen That screen shows how to enable driving the vehicle In drive screen the driver can s...

Page 15: ...System 3 Bosch Motorsport e GoKart_Powertrain__Young_Star__Manual 15 60 Illustration 8 Driving Screen of DDU 18 Illustration 9 Menu Screen of DDU 18 Illustration 10 Setting Screen of DDU 18 ...

Page 16: ...sure compensation element Illustration 11 Vehicle Control Unit VCU MS 40 Do not use the VCU MS 40 in vehicles different from applications intended for 4 1 1 Technical Data Maximum standby current 1 mA Power dissipation estimation of the VCU MS 40 depending on use case Weight approximately 500 g Outer dimensions approximately 123 x 142 2 x 43 1 mm 4 2 Energy Storages ES 5 2 4 The BOSCH MOTORSPORT e...

Page 17: ...ndustry standards regarding this product BOSCH MOTORSPORT is not responsible or liable for any damage or failure due to mis handling or poor maintenance once received and accepted by the CUSTOMER In the un likely event of a cell venting the Energy Storage ES 5 2 4 housing is designed to fail in a manner to allow gases to vent from the cells to the atmosphere At the end of battery life this product...

Page 18: ...l voltage measurement cell balancing protection against cell overvoltage and under voltage overcurrent short over tem perature and under temperature CAN communication diagnostic and status messages thermal prediction prediction of heating based on current consumption After a crash event all components with nominal operating voltage of 60 V DC or 30 V AC shall not be operated until it is ensured th...

Page 19: ...nal DIN 7092 M6 B Terminal DIN 7092 M8 4 3 Power Unit PU 5 10 The BOSCH MOTORSPORT e GoKart System is propelled by the e GoKart Power Unit PU 5 10 The Power Unit PU 5 10 consists of a 5 phase air cooled electrical claw pole machine electrically exited synchronous electric machine and an air cooled power electronic DC AC inverter with an integrated microcontroller logic controller The Power Unit PU...

Page 20: ...hine with integrated inverter air cooled cooling by integrated fans integrated rotor position sensor CAN interface for control communication Given performance data refer to the capability of the Power Unit PU 5 10 Any limitation of the torque that could be necessary e g limitation to 8 0 kW for electric Kart is con trolled by the Vehicle Control Unit VCU MS 40 For cooling on pulley side the air en...

Page 21: ... connector The VCU MS 40 controls operation of the Power Unit PU 5 10 In case of a detected fault in the Power Unit PU 5 10 the Power Unit PU 5 10 switches into idle mode does not react to torque requests and indicates a fault via CAN The product s operating safety is only ensured if the permissible conditions are maintained The CUSTOMER is responsible for appropriate usage of the Power Unit PU 5 ...

Page 22: ...ket s in the vehicle Screws for mounting the Power Unit PU 5 10 and the accessory brackets are not in the BOSCH MOTORSPORT scope of delivery Illustration 16 Pulley mounting 4 4 DC DC Converter The main function of the unidirectional DC DC converter is the power transfer from 48 V to 12 V The DC DC converter provides the supply power for all 12 V loads in the system and charges the 12 V battery For...

Page 23: ...r in overload condition The maximum continuous output current is 11 0 A Enable of the DC DC converter is con trolled by the Vehicle Control Unit VCU MS 40 4 5 Charger Energy Storage CH 5 1 2 Illustration 18 Charger Energy Storage CH 5 1 2 Dimensions 179 x 317 75 x 90 5 mm Weight approx 3 5 kg Sealed aluminum die cast housing built in fan CAN control interface compatible with BOSCH MOTORSPORT e GoK...

Page 24: ...1898 impedance shielding twisted pair etc The proposed setup does not require additional grounding Any additional grounding might lead to hazards or malfunction and is subject to agreement and validation with BOSCH MOTORSPORT Thermal integration The Charger Energy Storage CH 5 1 2 does not require any additional active cooling An integrated fan operates at higher temperatures If fan operation is i...

Page 25: ...bjects in this document and should be documented appropriately The battery swap procedure on the vehicle shall also be performed by instructed persons but will not be covered in this document Responsibility for correct pairing of batteries same balancing level and SOH is on OEM User side The Charger Energy Storage CH 5 1 2 is designed to be continuously AC supplied The AC supply may have to be rem...

Page 26: ...eeded Modification of the cable harness is strictly prohibited i e no different or additional con nectors than originally equipped may be applied A cable designed for dual battery charge shall not be used to charge a single battery pos sibility of short circuit at open ended connector Chargers Energy Storage CH 5 1 2 may not be used in parallel on the DC side The System of Charger Energy Storage C...

Page 27: ...ake contains a detection of the number and state of attached the Energy Storages ES 5 2 4 If all necessary conditions are fulfilled the attached batteries will perform a precharge of the DC line and charging begins within 5 s Deep discharged packs terminal voltage 32 5 V will be detected and refused for charge The charging control contains an intelligent parallel operation of multiple Energy Stora...

Page 28: ...rging has completed if the green LED is permanently on Before disconnecting the Energy Storages ES 5 2 4 the system shall be shut down either manually or automatically after 10 min manual shutdown by pressing I O button Shutdown can take up to 10 s Shutdown complete is indicated by the LEDs off Error conditions If an error is detected the condition is signaled by a blinking LED pattern If an inter...

Page 29: ... shall only be connected and disconnected in the Charger Energy Storage CH 5 1 2 OFF state LEDs off The setup shall be protected from avoidable impacts drop water mechanical shock Components that show visible damage must not be used Components which show faulty behavior e g tripping AC fuse must not be used If any component shows a different behavior than stated in this document the corres ponding...

Page 30: ... The display is monochrome white on black with LCD dot matrix D FSTN It has a resolution of 320 x 240 pixels dot pitch maximum 0 28 mm The active area is minimum 89 x 67 mm Supply voltage is 12 V nominal with reverse polarity protection Minimum voltage is 8 V and maximum voltage is 18 V The maximum current is 1 5 A 12 V The quiescent current is 200 μA target 12 V The display performs best in a tem...

Page 31: ...s in use All 48 V components shall be connected to a distribution point This might be traction net power distribution unit PDU Usage of two cable lugs on top of each other at the terminals of the Energy Storage ES 5 2 4 is not allowed Parallel Energy Storages ES 5 2 4 must be connected via dedicated rails or comparable solutions There is one common ground point of 48 V and 12 V ground located insi...

Page 32: ...the 12 V battery shall be disconnected terminal 30 Screws shall only be mounted into clean screw threads of the BOSCH MOTORSPORT e GoKart System components Before mounting the wiring harness the respective compon ent screw threads shall be checked for cleanliness Unused pins in any connector shall be sealed BOSCH MOTORSPORT components require longitudinally watertight cables to avoid propagation d...

Page 33: ...parallelism of 0 5 There shall be a minimum distance of 50 mm from the VCU MS 40 to the outer surface of the vehicle vehicle body This is to ensure that no external mobile transmitter e g in a cellular phone can disturb the system In case that there is an internal mobile transmit ter installed e g in vehicle sharing concepts the distance shall also be considered The wiring harness shall be mechani...

Page 34: ...l conditions shall be considered for vehicle integration position In order to provide maximum possible protection against vehicle crash effects the En ergy Storages ES 5 2 4 of the system should be mounted outside crash zones of the vehicle core After a crash event the Energy Storages ES 5 2 4 shall not be operated until it is ensured that no mechanical electrical and thermal deformation of compon...

Page 35: ...U 5 10 shall be installed under consideration of Sufficient air intake to cool the components of the Power Unit PU 5 10 shall be en sured splash water protected installation position dust protected installation position no critical radiant heat by other components The Power Unit PU 5 10 needs to be protected against stone chipping mud and any parts that could enter the Power Unit PU 5 10 which cou...

Page 36: ...late as the Power Unit PU 5 10 The Power Unit PU 5 10 shall be mounted electrically isolated to the vehicle chassis It shall be taken into account that connections with other metal parts e g gearbox may have an impact on required insulation of the Power Unit PU 5 10 to the vehicle chassis Power Unit PU 5 10 with clockwise main direction of rotation Nut Left hand thread Screw Right hand thread The ...

Page 37: ...ice or rework the nut shall be tightened with limited torque 105 to 111 Nm Tightening of the screw shall consider a torque limitation of 38 to 40 Nm The Power Unit PU 5 10 is mounted by screws to the accessory bracket s in the vehicle Screws to mount the Power Unit PU 5 10 with the accessory brackets are not in the BOSCH MOTORSPORT scope of delivery Only mounting points marked in Figure shall be u...

Page 38: ... accessory bracket The nominal width of the bracket including all tolerances shall be max 58 8 mm to en sure that the Power Unit PU 5 10 can be mounted adequately Illustration 29 Mounting points of the PU 5 10 The parallelism between vehicle support surface and the insulation bushing surface must be 0 05 mm Illustration 30 Parallelism of customer engine block Insulation bushing not necessary ...

Page 39: ...nd free of prints Screws to connect the wiring harness to the Power Unit PU 5 10 are in the responsibility of the CUSTOMER At assembly or disassembly of the wiring harness to or from the B B bolts of the Power Unit PU 5 10 the used tightening torque shall not exceed the maximum allowed torque according to VDA specification The screw connection for the assembly of the cable lug to the B B bolt has ...

Page 40: ... DDU 18 Tightening torque of 1 Nm and the screw in depths of 6 mm shall not be exceeded Therefore the length of the screws must be appropriate Different screws lengths are pos sible for different mounting locations It shall be ensured that the tightening for mounting at the handlebar is designed in that way that loosing of the screws is prevented over lifetime Illustration 33 Mounting of faceplate...

Page 41: ...he components are fixed like shown in the following picture Display Unit DDU 18 Battery 1 Battery 2 Power Unit PU 5 10 Illustration 34 Kart chassis with fixed components 6 1 Implement the Components 6 1 1 48 V Wiring Harness Place a holder for the fuse on the black box with two M4 screws washers and self locking nuts Illustration 35 48 V wiring harness Relay Mounting ...

Page 42: ...U 5 10 Energy Storage ES 5 2 4 1 Energy Storage ES 5 2 4 2 Use cable fixers to fix the wiring harness to the chassis On the following picture you can see how to place the wires The turquoise box in the rear area symbolizes the black box The red lines symbolize the cables of the 48 V wiring harness They lead from the black box to the Power Unit PU 5 10 and the Energy Storages ES 5 2 4 Illustration ...

Page 43: ...PU 5 10 wiring fixed on the chassis Place the cables close to the structure of the kart as shown in the following picture Illustration 39 Cables placed close to the structure Connect 48 V wiring with Energy Storage ES 5 2 4 1 Illustration 40 How to connect the Energy Storage ES 5 2 4 Connect 48 V wiring with Energy Storage 5 2 4 2 ...

Page 44: ...s carefully at the chassis of the kart Illustration 41 Cables placed close to the structure 6 1 2 12 V Wiring Harness Implement the 12 V wiring harness in the chassis after you have installed the 48 V wiring harness On the following figure you see the 12 V wiring harness All wirings are marked with yellow labels Illustration 42 12 V wiring harness delivery state ...

Page 45: ... 12 V Battery 12V GND Remote HW rte_spedlim Brake pressure sensor p_brake middle top Charger CAN charge_CAN Brake light brake_sw DC DC converter DC DC steering wheel Display Unit DDU 18 connector SP stear Display Unit DDU 18 remote connector rte_DDU front side Acceleration pedal sensor s_accped Brake inductive sensor p_brake right side Battery 2 batt_2 ON OFF switch open end wiring See Figure Neut...

Page 46: ...with relay Housing With this measure the rough posi tioning of the wiring harness is specified After that you can install all wiring in the chassis Left side After you put the relay housing on its fixation you start with the left side of the wiring To simplify the wiring lead the 12 V harness above the 48 V wiring harness as shown in the following picture ...

Page 47: ... to prevent movement of the wiring and contact to moving parts Start with connecting your 12 V supply with our open end wiring Illustration 44 Left side wiring fixed on the frame Middle wiring Illustration 45 Charge CAN is connected to the HV wiring Brake light and DC CS are nor connected Charger CAN charge_CAN Brake light brake_sw DC DC converter DC DC Please fix the Anderson Connector direct wit...

Page 48: ...the brake light wiring as described Pin 1 Kl 15 12 V Pin 2 switched 12 V Pin 3 GND Right side Illustration 47 Right side wiring Fix all wiring for the right side with a cable fixer Battery 2 batt_2 ON OFF switch open end wiring see Figure Neutral Drive switch open end wiring see Figure SOC LEDs LED SOC_1 LED SOC_2 LED SOC_3 LED SOC_4 Key switch open end wiring ...

Page 49: ...end wiring Illustration 49 At the old five wire cable the green wires were gray Fix the wiring on the emergency switch Neutral Wiring is not connected Drive Wiring is connected Neutral Drive switch open end wiring Illustration 50 How to connect the wiring on the LED SOC LEDs LED SOC_1 LED SOC_2 LED SOC_3 LED SOC_4 wiring White GND wiring Purple ...

Page 50: ... up chassis 50 60 e GoKart_Powertrain__Young_Star__Manual Bosch Motorsport Illustration 51 How to fix the wiring on the key switch Illustration 52 Key switch open end wiring Illustration 53 Power Unit PU 5 10 wiring fixed on the PU 5 10 ...

Page 51: ...ung_Star__Manual 51 60 Illustration 54 DDU 18 wiring fixed at the seat It is important that the wiring intersection is mounted at the end of the seat DDU 18 connector SP stear DDU 18 remote connector rte_DDU Illustration 55 DDU 18 connector should be fixed on the chassis via cable fixer ...

Page 52: ... should be fixed via cable fixer Please have a look on the wiring it is not perfectly fixed It can hook on the chassis Green LED GND Grey Switch Black Switch Purple LED Illustration 57 How to solder the wiring on the Boost Switch Please solder the open end wiring to the pins of the switch Purple LED Green LED GND Grey Switch Black Switch ...

Page 53: ...anual 53 60 Pin 1 yellow Pin 2 brown Illustration 58 How to solder the wiring on the Reverse Switch Please solder the open end wiring to the pins of the switch Brown Switch Yellow Switch Illustration 59 Please fix the wiring on the steering wheel Illustration 60 Fix the wiring under the metal sheet ...

Page 54: ...n the Wiring intersection by the seat mounting the wiring for the front has to be fixed under the metal sheet Acceleration pedal sensor s_accped Brake inductive sensor p_brake Illustration 62 Fixed connector in front of the pedal system 6 1 3 Acceleration pedal sensor The Acceleration pedal sensor should be mounted with the mark facing in wiring direc tion Mark Point ...

Page 55: ...sis 6 Bosch Motorsport e GoKart_Powertrain__Young_Star__Manual 55 60 Illustration 63 Position of the Acceleration pedal sensor Illustration 64 Screws position Check Sensor mark position Screws position Illustration 65 Acceleration pedal fixed ...

Page 56: ... the BOSCH MOTORSPORT calibration adapter The following picture shows the needed parts Illustration 67 Multimeter with calibration adapter Please connect the calibration wiring harness with the digital multimeter GND blue connector in COM Sig 1 green connector in V USB connector with a Laptop 5 V supply Acceleration pedal connector with the acceleration sensor Acceleration Pedal Position Sensor Si...

Page 57: ...necessary Illustration 68 Implemented brake inductive sensor 6 1 5 Pressure sensor Fix the pressure sensor with a suitable tool After implementation the brake line must be vented before the first drive At the end connect the brake pressure sensor with the wir ing harness Label p_brake Illustration 69 Brake pressure sensor implemented in the brake liner 6 1 6 Switches and LEDs The switches and LEDs...

Page 58: ...Young_Star__Manual Bosch Motorsport Illustration 70 Components fixed metal sheet 6 2 Vehicle Control Unit VCU MS 40 At the end of the wiring harness implementation the Vehicle Control Unit VCU MS 40 can be fixed on the black box Please use M3 screws with a washer and Loctite ...

Page 59: ...Troubleshooting 7 Bosch Motorsport e GoKart_Powertrain__Young_Star__Manual 59 60 7 Troubleshooting For troubleshooting please contact motorsport bosch de ...

Page 60: ...Bosch Engineering GmbH Motorsport Robert Bosch Allee 1 74232 Abstatt Germany www bosch motorsport com ...

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