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Online Measurement and Calibration | 13

Bosch Motorsport

Vehicle_Control_Unit_VCU_Manual

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13.2 Online calibration of measurement channels

– Analog sensors drift with age, temperature, etc.

– Manual calibration is necessary

– Solution: online offset calibration

– Example: acceleration sensor

13.2.1 Enable online offset calibration for measurement

channel

During creation of the measurement channel

Summary of Contents for VCU

Page 1: ...Vehicle Control Unit VCU Manual Version 1 3 02 07 2020 ...

Page 2: ... Limits 36 10 CAN Configuration 37 10 1 CAN Bus Trivia 37 10 2 CAN input 38 10 3 CAN output 44 10 4 Multiplexer 46 11 Analog and Frequency Inputs 49 11 1 Analog inputs 49 11 2 Configuring inputs 50 11 3 Configuring computed sources 64 11 4 Hysteresis 65 12 Power Stages 69 13 Online Measurement and Calibration 70 13 1 Setting up an online measurement 70 13 2 Online calibration of measurement channe...

Page 3: ...ning the Unit 116 19 GPS Sensor 118 19 1 GPS Global Positioning System 118 19 2 Protocol 118 19 3 Sensor recommendation 118 19 4 Measurement labels 121 19 5 GPS troubleshooting 122 20 Fuel Consumption Calculation 124 20 1 Setting up fuel consumption calculation and tank management 124 20 2 Fuel consumption diagnosis counter reset 125 20 3 Example 126 21 Predated Laptime 127 21 1 Setting up the pre...

Page 4: ...ow the application hints step by step Do not hesitate to contact us contact data can be found on the last page of this document Important information on Electromagnetic Conformity To avoid unwanted interference with the environment people animals electronic devices or unwanted harm to the environment it is mandatory that the user of the Vehicle Control Unit VCU carries out an appropriate analysis ...

Page 5: ...Danger DANGER Nature and source of danger Consequences Warning of death or serious physical injury which are sure to occur if ignored Warning WARNING Nature and source of danger Consequences Warning of death or serious injury which can occur if this is not observed Caution CAUTION Nature and source of danger Consequences Warning of slight bodily injury in case of Disregard Notice NOTICE Nature and...

Page 6: ... unswitched battery positive rail same as battery positive terminal KL 31 is an unswitched ground rail same as battery negative terminal Be careful to observe current limits of wires and connector pins G Engine_GND GND_Starpoint Chassis KL31 LS_GND_1 LS_GND_2 Main Switch UBAT Star connection term30 positive terminal Electric Loads IGN Switch KL15 SENSPWR5 SENSGND active Sensor ANA_IN xx NTC Sensor...

Page 7: ...lopment automatic code and documentation generation It offers real time Ethernet functionality to exchange e g data used in control algorithms between devices guaranteed latency time 1 ms This device comes with a basic software consisting of operating system H W drivers and low level functions like pin setup diagnostics etc The customer can freely develop his own application software using the MAT...

Page 8: ...Hz can be enhanced by Upgrade I O Package see below Power Supplies 12 V 400 mA each 5 Switchable 5 V 12 V 400 mA each 5 Max overall current 4 A on all 12 V 2 A on all 5 V Precision 12 V 1 on the pin Precision 5 V 0 1 on the pin Sensor ground 20 can be enhanced by Upgrade I O Package see below Adaptation and Documentation Function documentation Automatically created during code genera tion MatLab c...

Page 9: ... 2 A each PWM 10 kHz Power Supplies 5 x12 V 400 mA each 5 switchable 5 V 12 V 400 mA each The tooth count differential between any two of the PWM inputs is available two meas ure e g shaft torsion Upgrade Real Time Ethernet Enables the VCU to operate as a real time Ethernet master or slave Guaranteed latency time of 1 ms Ideal for time critical data transfer as needed in online control algorithms ...

Page 10: ...al Bosch Motorsport Connectors Connector LIFE red AS018 35PN Mating connector AS618 35SN not in cluded Connector SENS A yellow AS018 35PA Mating connector AS618 35SA not in cluded Connector SENS B blue AS018 35PB Mating connector AS618 35SB not in cluded ...

Page 11: ...FE 14 I I_DIGIN13 0 to 5 V LIFE 15 I O B_D_RS232_RX 12 V LIFE 16 I O B_D_RS232_TX 12 V LIFE 17 I O B_D_ETH2TXN ETH LIFE 18 I O B_D_ETH2TXP ETH LIFE 19 I I_DIGIN14 0 to 5 V LIFE 20 G GND GND LIFE 21 I I_S_LAPTRIG 0 to 5 V LIFE 22 I O BI_TIMESYNC 0 to 5 V LIFE 23 I O B_D_SERCOS2RXN ETH LIFE 24 I O B_D_SERCOS2RXP ETH LIFE 25 I O B_D_ETH2RXN ETH LIFE 26 I O B_D_ETH2RXP ETH LIFE 27 I O B_D_ETH3TXN ETH ...

Page 12: ...I O BI_CAN1_L 0 to 5 V LIFE 57 I I_DIGIN16 0 to 5 V LIFE 58 O G_USB_GND float LIFE 59 I I_DIGIN07_HALL 0 to 5 V LIFE 60 I I_DIGIN06_HALL 0 to 5 V LIFE 61 I O B_D_ETH1TXN ETH LIFE 62 I O BI_CAN2_H 0 to 5 V LIFE 63 V V_UBAT VBAT LIFE 64 I I_DIGIN05_HALL 0 to 5 V LIFE 65 I O B_D_ETH1RXP ETH LIFE 66 I O B_D_ETH1TXP ETH Connector SENS A yellow Mating connector AS618 35SA Pin I O Signal Level Power SENS...

Page 13: ...9 I I_THERM2_P 0 to 5 V SENS A 30 O O_DIGOUT4 5 V 50 mA SENS A 31 O O_DIGOUT3 5 V 50 mA SENS A 32 O O_DIGOUT2 5 V 50 mA SENS A 33 O O_DIGOUT1 5 V 50 mA SENS A 34 O O_VSENS18_12V 12 V 250 mA SENS A 35 O O_VSENS07_12 5V 5 V 12 V 250 mA SENS A 36 O O_VSENS06_12 5V 5 V 12 V 250 mA SENS A 37 O O_VSENS17_12V 12 V 250 mA SENS A 38 I I_THERM2_N 0 to 5 V SENS A 39 I I_ANA08_5V 0 to 5 V SENS A 40 I I_ANA09_...

Page 14: ...o 5 V SENS B 04 O O_VSENS02_12 5V 5 V 12 V 250 mA SENS B 05 O O_VSENS03_12 5V 5 V 12 V 250 mA SENS B 06 O O_VSENS15_12V 12 V 250 mA SENS B 07 O O_VSENS14_12V 12 V 250 mA SENS B 08 I I_LVDT2_SEC_M 5 to 5 V SENS B 09 O O_LVDT2_PRI1 5 to 5 V SENS B 10 O O_VSENS01_12 5V 5 V 12 V 250 mA SENS B 11 O O_VSENS12_12V 12 V 250 mA SENS B 12 O O_VSENS13_12V 12 V 250 mA SENS B 13 O G_SENSGND02 GND 2 A fused SEN...

Page 15: ...43 O O_LSOUT3 VBAT 2 A SENS B 44 O G_SENSGND13 GND 2 A fused SENS B 45 V V_UBAT VBAT SENS B 46 G GND GND SENS B 47 I I_ANA05_5V 0 to 5 V SENS B 48 I I_ANA11_5V 0 to 5 V SENS B 49 I I_ANA14_5V 0 to 5 V SENS B 50 I I_ANA15_5V 0 to 5 V SENS B 51 O O_HSOUT2 VBAT 8 A SENS B 52 O G_SENSGND14 GND 2 A fused SENS B 53 O G_SENSGND15 GND 2 A fused SENS B 54 I I_ANA01_5V 0 to 5 V SENS B 55 I I_ANA02_5V 0 to 5...

Page 16: ... The Ethernet ports have cable auto crossover functionality RS232 port The Vehicle Control Unit VCU has one RS232 serial port dedicated to inbound GPS data Vehicle diagnosis connector The Bosch Motorsport vehicle diagnosis connector is used as a standard interface to con nect the vehicle to a PC e g via a MSA Box II Loom connector AS012 35SN Pin Name Description Used for Vehicle Control Unit VCU P...

Page 17: ...Mechanical Drawing 7 Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 17 136 7 Mechanical Drawing 86 6 20 86 6 16 YAW RATE SENSOR Drehratensensor ...

Page 18: ...tup configuration and calibration RaceCon Measurement data analysis WinDarab Set up the 100 Mbit Ethernet connection to the Vehicle Control Unit VCU The Ethernet port has cable auto crossover functionality 8 1 1 Setting up a new RaceCon Project The following screenshot shows an overview of the RaceCon Main Screen with its areas All sub windows are resizable and dockable You can find them under the...

Page 19: ...wo symbols VCU Logger and VCU ECU 3 Unlike other Bosch Motorsport devices the Vehicle Control Unit VCU needs two dif ferent program archives the Logger program archive and the ECU program archive For the Logger program archive go to the Toolbox and select the Vehicle Control Unit VCU Drag it into the Main Area A pop up window appears to specify the Vehicle Control Unit VCU Logger program archive ...

Page 20: ...sport 4 In the next step the ECU needs to be specified A pop up window appears to specify the ECU program archive 5 Download the firmware for the Vehicle Control Unit VCU from www bosch motorsport com An information shows if the archive is valid or not 6 Click Next ...

Page 21: ...h The Vehicle Control Unit VCU is inserted into the project and RaceCon tries to con nect to the device RaceCon detects configuration differences between the Vehicle Control Unit VCU and the RaceCon project and asks for permission for data download 9 Click Yes to download the configurations to the device or No to continue without downloading the data ...

Page 22: ...113 The download starts and the Vehicle Control Unit VCU carries out a reset After the reset RaceCon reconnects to the Vehicle Control Unit VCU Local configura tion on both the PC and Vehicle Control Unit VCU match indicated by green back ground and dot The Vehicle Control Unit VCU is now connected to RaceCon Green background and dot indicate matching configuration For further information on the c...

Page 23: ...y other Vehicle Control Unit VCU When purchasing a software feature package you have to tell Bosch the ECU ID code The ECU ID code is device specific and can be found in the features info window shown in the screenshots below If you have not purchased an optional software feature package the next steps can be skipped 1 Ensure a connection to the device 2 To activate a feature proceed as follows Fo...

Page 24: ...click on the feature you want to activate A feature unlock window appears 5 Enter the activation key you received for this feature on this device and click OK when done The feature s status changes to unlocked 6 Perform these steps to activate other features you purchased 7 Switch the car s ignition off and on again to cycle the power of Vehicle Control Unit VCU ...

Page 25: ... recordings 1 Click on the Logger tab to go to the page Logger 2 Use the search bar in the Data window to search for ub measurement channel for battery voltage Search for ub 3 Drag and drop the ub measurement channel into the recording area Drag Drop 4 Click on the Download button in the upper left corner The configuration download starts and the Vehicle Control Unit VCU carries out a re set Now y...

Page 26: ... start conditions recording starts immediately 5 Start the WinDarab software 6 Disconnect the Vehicle Control Unit VCU network cable 7 Click on the Read Data from Logging Device icon 8 Choose your logger and click OK when done Click read data from logging device The Data Logger Import dialog opens ...

Page 27: ... Control Unit VCU network cable 12 Click on the Current Import tab 13 Click on Import in the lower right corner If the Import all on connect box is checked the data transmission from the Vehicle Control Unit VCU starts automatically Measurement files are stored automatically in the folder defined under Settings 14 Click on Close when the transmission has finished 15 Click on the Start button and c...

Page 28: ...ime and date The Vehicle Control Unit VCU is equipped with a real time clock which is supplied by an internal accumulator Once this accumulator is charged correctly by 12 V supply of the display Date Time can be programmed by RaceCon Reassure that the time is set correctly if the device has not been used for more than two weeks 1 Connect the Vehicle Control Unit VCU to the PC 2 Click on the Set da...

Page 29: ...lternatively click on Set Date Time in the context menu of the device A Set Date Time menu opens 4 Set the current local date and time as coordinated universal time 5 At Set a specific date time click and type on the value you want to change or choose from the dropdown menu ...

Page 30: ...ating a new Math Channel 1 Follow the steps shown in the screenshot 1st Double click on Math Channels in the Project tree 2nd Click on Add channel The Create edit math channel window appears 2 Define the math channel using the following configuration possibilities a b c d e f g h a Enter the name of the math channel b Enter a description of the math channel c Enter the formula d Select the logical...

Page 31: ...RaceCon project Creating a new Conditional Function 1 Follow the steps shown in the screenshot 1st Double click on Math Channels in Project Tree 2nd Click on the dropdown arrow beside Add channel 3rd Choose Conditional function The create edit math channel window appears 2 Define the math channel using the following configuration possibilities a b c d e a Enter the name of the conditional function...

Page 32: ...ed in Name The reset value is always set for the new variable entered in Name before the If condition becomes TRUE for the first time after power up when the If condition changes state from FALSE to TRUE An example of a condition to set up the maximum front brake pressure is given on the next page The conditional function is displayed in the Vehicle Control Unit VCU math channel win dow Example Se...

Page 33: ... p_br_front_mx is set to 40 As p_br_front falls below 20 the IF condition turns to FALSE Now the OTHERWISE condition is triggered Because the condition p_br_front_mx sets the value of p_br_front_mx and the value is already set to 40 nothing changes When p_br_front rises to 40 the IF condition changes to TRUE again and triggers the THEN condition Now the reset value 10 is used for p_br_front_mx in ...

Page 34: ...on to be compared Range Choose the measurement channel or condition the operator and define the minium and maximum value Multiple Choose the measurement channel or condition the operator and enter the value of up to 5 constants d Enter the minimal time to detect the signal of the measurement channel to avoid high frequent switchovers e Enter the time the signal of the measurement channel is delaye...

Page 35: ...h measurement channel with binary values to be compared Combine multiple conditions by adding AND or OR relations To negate a condition click with the right mouse button on the condition and se lect Negation Combine several up to 16 conditions Click Next to go to the next page Choose the output setting of the result Constant TRUE FALSE Result is as a constant with the value TRUE or FALSE Blinking ...

Page 36: ...crashing and rebooting Main factors influencing the CPU load are Number and complexity of math channels Number and complexity of conditions CAN traffic on both CAN lines Display configuration especially displaying pictures Logger configuration total logging rate kB s conditional measurement rates To help respecting the limit of 85 CPU load the Vehicle Control Unit VCU creates an er ror memory entr...

Page 37: ...o CAN messages out put frequency and row counter are configurable CAN gateway functionality transfer from one bus to another 10 1 CAN Bus Trivia CAN Message 11 Bit standard or 29 Bit extended identifier Up to 8 bytes of data payload CAN Bus Needs termination resistors in wiring harness All devices connected to the bus must use identical data rate Configuration of bus data rate in the CAN messages ...

Page 38: ...read from CAN bus Import Vector CAN database DBC channel configuration Export RaceCon CAN configuration to file Import RaceCon CAN configuration from file Display CAN bus properties Baudrate Create new CAN output message Export Vector CAN database DBC channel configuration 10 2 2 Create new CAN Input channel 1 Double click on any CAN bus item to open the CAN messages overview 2 Select Add CAN IN a...

Page 39: ...CAN Configuration 10 Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 39 136 3 Insert the name and description of the channel 4 Click OK when done The channel is listed in the Data window ...

Page 40: ...Byte Some CAN devices need to be addressed by a byte represented CAN channel The ad dress can be assigned in this window and is illustrated by a bargraph a b c d e a Enter CAN message ID If extended IDs 29 bit are used check the box b If replacement values are used specify time out period and raw value c If a multiplexer row counter is used check the box ...

Page 41: ... IDs 29 bit are used check the box b If replacement values are used specify time out period and raw value c If a multiplexer row counter is used check the box d Enter data position length and format e The bargraph shows assignment of the bytes Red colored fields show the assignment of the data bytes Orange colored fields show the assignment of the multiplexer bytes Conversion to physical value a b...

Page 42: ...surement sheets The CAN channel can be automatically inserted into a measurement sheet Insert a name for a new sheet or select an existing sheet from the list box For an online view of the value measured by the Vehicle Control Unit VCU insert the channel in an online measurement sheet which is described in the chapter Setting up an online measurement 70 10 2 4 Online view of CAN channels in vehicl...

Page 43: ...ent element Drag Drop The measurement element displays the values of the assigned channel 6 Connect PC to the vehicle and switch to Race Mode by clicking F11 on the key board to display online data 10 2 5 Import a CAN database DBC file 1 Right click on CAN Input of desired bus CAN1 or CAN2 2 Select Import DBC file from menu A file browser opens 3 Select DBC file to import and click OK when done A ...

Page 44: ...d in the Data window 10 3 CAN output 10 3 1 Output configuration Create new CAN output message Export RaceCon CAN output configuration to file Import RaceCon CAN out configuration from file Display CAN bus properties Baudrate 10 3 2 Create a new CAN output message channel Double click on any CAN bus item to open the CAN messages overview Select Add CAN OUT and choose the desired CAN bus for the ne...

Page 45: ...ow opens Enter name of message description CAN Id and Grid output interval Optionally specify a multiplexer Definition of CAN message Content of message Click on Add channel or Add constant this opens the Add new CAN out channel window Select the desired measurement channel and specify the message settings ...

Page 46: ...Out constant window appears 3 Define the name of the constant the required value in hex and define the CAN chan nel settings 4 Click OK when done Click here 10 4 Multiplexer Row counter concept If certain channel messages are not time critical and can be imported or exported slowly you can use a multiplexer to put several channel messages on one message identifier Re use multiplex of message ident...

Page 47: ...annel 3 Check the box Use Multiplexer and configure the multiplexer for the new CAN IN channel 4 To configure the multiplexer for a CAN OUT channel select Add CAN OUT 5 Check the box Use Multiplexer and click on the button Add row to split the mes sage identifiers into several rows 6 Click on one row and select Add channel to assign a channel to the row The Add new CAN out channel dialog opens 7 S...

Page 48: ...10 CAN Configuration 48 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport 10 The channel message is assigned to the selected fields 11 Click OK when done ...

Page 49: ...everal subchannels are available Measurement labels with the characters raw show the exact values in mV Measurement labels with the characters _fi show filtered values The word name in the table is a placeholder for the channel s name Measurement label Function raw_name mV value of sensor raw_name_fi Filtered mV value of sensor name Physical value of sensor name_fi Filtered physical value Filtered...

Page 50: ...efined Bosch sensor with the Bosch Sensor Wizard 1 Click on Measurement Sources in the Toolbox 2 To expand the list of I O Channels click on in the Vehicle Control Unit VCU Pro ject Tree 3 Drag the Bosch Sensor Wizard from the Toolbox and drop it on the desired analog input channel in the Vehicle Control Unit VCU Project Tree Drag Drop ...

Page 51: ...sh when done The Create channel window opens 5 Enter the channel name and description 6 Click Ok when done The channel is inserted into the Vehicle Control Unit VCU Project Tree Channel is linked to ANA03 Input pin Pull up resistor is activated Calculation of physical value with characteristic curve Available measurements for channel Measurement label Function raw_name mV value of sensor raw_name_...

Page 52: ... VCU Pro ject Tree 3 Drag the Sensitivity Offset analog signal source from the Toolbox and drop it on the desired analog input channel in the Vehicle Control Unit VCU Project Tree A Sensit ivity Offset Wizard opens 4 To activate the internal pullup resistor check the box The internal pullup resistor is used to get a 5 V signal at the analog channel of the Vehicle Control Unit VCU It al lows you to...

Page 53: ...nel Enter physical limits of the sensor Choose data type of the measurement variable Check box to enable online calibration of offset and enter desired physical offset value Enter name to automatically create a new measurement sheet NOTICE Working with automatically created measurement sheets is ex plained in chapter Setting up an online measurement 70 7 Click Finish when done 8 Enter a channel na...

Page 54: ... filtered physical value 11 2 3 Configuring a generic nonlinear sensor Example Thermistor 5 kOhm From sensor data sheet resistance values over temperature The sensor has a nonlinear behavior Use characteristic curve for linearization Input voltage is the ratio between pull up resistor and thermistor Pin Thermistor 5V 3 kOhm 1 Click Measurement Sources in the Toolbox 2 To expand the list of I O Cha...

Page 55: ... box The Vehicle Control Unit VCU pull up resistor is used to get a 5 V signal at the analogue channel of the Vehicle Control Unit VCU It allows you to use a push button The fixed value of the internal pull up resistor is 3 010 Ohm If using an additional external pull up resistor set up the overall resistance 5 Click Next when done The second part of the Sensitivity Offset Wizard opens ...

Page 56: ...aracteristic Curve Wizard opens Physical limits of channel Enter physical limits of the channel Choose data type of the measurement variable This sensor does not need offset calibration Enter name to auto matically create a new measurement sheet 7 Click Finish when done 8 Enter channel name and description 9 Click OK when done The channel is inserted into the Vehicle Control Unit VCU Project Tree ...

Page 57: ...4 Configuring a multipoint adjustment Example Measurement of wheel force Physical property wheel force not directly measureable Load transfer through suspension kinematics Physical value at sensor position defined by vehicle Curve definition by online adjustment at vehicle 1 Click on Measurement Sources in the Toolbox 2 Expand the list of I O Channels by clicking on in the Vehicle Control Unit VCU...

Page 58: ...heck the box The internal pullup resistor is used to get a 5 V signal at the analog channel of the Vehicle Control Unit VCU It al lows you to use a push button The fixed value of the internal pullup resistor is 3 01 kOhm If using an additional external pullup resistor set up the overall resistance 5 Click Next when done The second part of the Multipoint Adjustment Wizard opens ...

Page 59: ...t Wizard opens Physical limits of channel Enter physical limits of the sensor Choose data type of the measurement variable Enable additional online calibration Enter name to auto matically create a new measurement sheet 7 Click Finish when done 8 Enter channel name and description 9 Click OK when done The channel is inserted into the Vehicle Control Unit VCU Project Tree Channel is linked to ANA06...

Page 60: ...chapter Online calibration of measurement channels 75 of this manual NOTICE Working with automatically created measurement sheets is ex plained in chapter Setting up an online measurement 70 11 2 5 Digital filter details Vehicle Control Unit VCU uses A D converter oversampling and digital filtering to record ing rate Digital filters eliminate out of band noise Cut off frequency automatically adjus...

Page 61: ... over several samples Filtered signal is delayed with respect to real time signal Vehicle Control Unit VCU filters have constant frequency independent delay Delay e g 22 samples at 10 ms is corrected during recording No delay filtered vs unfiltered in recorded data Correction is of course not possible for real time data display online PWM out Use filtered data for recording use unfiltered data for...

Page 62: ... Velocity digital signal source from the Toolbox and drop it on the desired REV input channel in the Vehicle Control Unit VCU Project Tree Drag Drop The Velocity Wizard opens 4 Select the sensor type The DDU10 works with Halleffect and DF11 sensors 5 Click Next 6 Define the settings for the sensor ...

Page 63: ...k Finish when done 8 Enter the channel name and description 9 Click OK when done The channel is inserted into the Vehicle Control Unit VCU Project Tree Channel is linked to REV01 Input pin has hall interface Number of teeth Wheel circumference Available measurements for channel Measurement label Function raw_name mV value of sensor raw_name_fi filtered mV value of sensor name physical value of sen...

Page 64: ...igger covered in a special separate section Example Sensitivity offset calculation on input channel 1 Click Measurement Sources in the Toolbox 2 Drag the Sensitivity Offset computed source from the Toolbox and drop it on Com puted Channels in the Vehicle Control Unit VCU Project Tree Drag Drop A Computed Sensitivity Offset Wizard opens Choose input channel Choose unit group and unit of output Ente...

Page 65: ...U Project Tree NOTICE Working with automatically created measurement sheets is ex plained in chapter Setting up an online measurement 11 4 Hysteresis The hysteresis function avoids the high frequent switchover of the measurement channel value The hysteresis can be adjusted for each input measurement channel individually and can be used for further processing 1 Click Measurement Sources in the Tool...

Page 66: ...ent variable Check the box to force the channel s quantization if the quantization should be a fixed value in the whole CAN system Enter name to automatically create a new measurement sheet 4 Click Finish when done 5 Enter channel name and description 6 Click OK when done The channel is inserted into the Vehicle Control Unit VCU Project Tree Channels available in Computed sources Available measure...

Page 67: ... 4 2 Setting up calculated speed 1 Click on tab System Overview 2 Click on Measurement Sources in the Toolbox 3 Drag the Speed computed source from the Toolbox and drop it on the project name in the Vehicle Control Unit VCU Project Tree Do not drop it on Vehicle Control Unit VCU Drag Drop A Calculated Speed Wizard opens Choose device Choose input source internal external Choose driven axle Choose ...

Page 68: ...Analog and Frequency Inputs 68 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport Speed calculation in DDU Project Tree Measurement channels calculated speed and calculated distance Configuration window ...

Page 69: ...ture power stage High side shortcut to GND overcurrent overtemperature shortcut to U_batt in switched off state open load current measurement and plausibilisation in CCA Suggestion for the implementation of a current control There is no analogue circuitry for a current control However the current measurement values can be used for the calculation of an appropriate pwm dutycycle in the Customer Cod...

Page 70: ...on System status and diagnosis Check and calibrate sensors in the vehicle Live display of sensor values on the PC Use RaceCon for diagnosis online measurement and calibration Communication interface Ethernet Communication protocol XCP 13 1 Setting up an online measurement Vehicle Control Unit VCU supports online measurement of sensor values and diagnostic variables 1 Expand Measurement Container a...

Page 71: ...corner In the menu for sheets you will find buttons to add delete and rename new sheets 4 To change between different sheets click on the tabs on the bottom of the Calibra tion Measuring window Tabs to switch between sheets To add an element to a measurement sheet perform the following steps 5 Drag a measurement element from the Toolbox and drop it on the measurement sheet Drag Drop 6 Select the d...

Page 72: ...ent types of measurement elements Vertical Bar graph style Temperature gauge Horizontal Bar graph style Circular gauge Numeric indicator Measurement label Oscilloscope Chart 13 1 1 Automatic creation of measurement sheets RaceCon can create measurement sheets automatically You can create and use measurement sheets with the Vehicle Control Unit VCU as well as with all other devices connected to Rac...

Page 73: ...ort Vehicle_Control_Unit_VCU_Manual 73 136 Drag Drop 1 During the configuration of a measurement channel select a measurement sheet from the list box or enter a name for a new measurement sheet Select existing sheet from list or enter name of new sheet ...

Page 74: ...in the Project Tree under Measurement Container and Device Channels If the Vehicle Control Unit VCU is connected to RaceCon and the status is green live values of the channels are shown 13 1 2 Using the measurement sheets 1 When RaceCon is online press the F11 key to switch from Design Mode into Race Mode The measurement sheet is extended to full screen The button for offset calib ration is active...

Page 75: ...13 2 Online calibration of measurement channels Analog sensors drift with age temperature etc Manual calibration is necessary Solution online offset calibration Example acceleration sensor 13 2 1 Enable online offset calibration for measurement channel During creation of the measurement channel ...

Page 76: ...line offset calibration Vehicle Control Unit VCU has to be connected to RaceCon to calibrate the sensor s offset 1 Apply the desired physical condition to the sensor e g 1 G to an acceleration sensor 2 Open the measurement channel s online page by double clicking on the measure ment channel name in the Data Area 3 Enter the physical target value e g 1 G and press the Calibrate button Calibration t...

Page 77: ... a multipoint adjustment 57 2 Download the configuration on the Vehicle Control Unit VCU To connect the Vehicle Control Unit VCU to RaceCon see chapter Setting up a new RaceCon Project 3 Click on the desired channel in the Vehicle Control Unit VCU Project Tree 4 Double click on a measurement channel in the Data Area to open the online view Click to open measurement channels in data view Double cli...

Page 78: ...e_Control_Unit_VCU_Manual Bosch Motorsport 8 Press the Calibrate button of the desired calibration point 9 Repeat for all curve points 10 Click Close when done The calibration curve is displayed in the online view Adjustment points vs offset adjustment ...

Page 79: ...external sensor interfaces Up to two independent recordings Measurement rate 1 ms to 1 s Two global start conditions thresholds Up to 16 measurement conditions fast slow switches 14 2 Configuration of Recordings 1 Expand the Logger list by clicking on in the Vehicle Control Unit VCU Project Tree 2 Double click on Logging in the Vehicle Control Unit VCU Project Tree The recording configuration is d...

Page 80: ...irectly Tabs to access conditions settings and statistics Variables can be grouped 4 To add a measurement channel to a recording select the wanted channel drag and drop it onto the measurement group Recording properties Drag measurement channels into group 5 To edit channel settings mark the channel s and click Edit Recording Channel s ...

Page 81: ...s defined or the recording condition is false measurement channels are recorded at the value chosen in Rate If the condition is true measurement channels are recorded at the value chosen in True rate 6 Click OK when done 14 2 1 Adding a recording group Recording channels can be grouped These groups will also be visible in Darab and will help to get a better overview during the data analysis 1 To a...

Page 82: ...tion file if provided by your Bosch Sup port Engineer d Choose or create the condition to start recording e Enter a password hint and a password optional f Setting for automatic fragmentation Do not change 14 2 3 Recording statistics The tab Statistics shows the channels allocation and their current data rate related to the transmission frequency of the Vehicle Control Unit VCU and the whole trans...

Page 83: ... recording threshold s not reached 254 Measurement correctly initialized Vehicle Control Unit VCU is recording data 255 Values less than 254 indicate an error state 14 3 USB recording This function requires the installation of Software Upgrades Look into the datasheet of your device to see which upgrades are available for your device Software Upgrade USB_DATA enables USB recording To activate Soft...

Page 84: ...Press Format An USB device is recognized by Windows as a storage medium but it can only be initial ized with RaceCon and read with WinDarab 14 3 1 Recording data on USB device 1 Plug an USB device to Vehicle Control Unit VCU 2 Prepare a recording configuration in RaceCon 3 Power on the system and connect with RaceCon to the vehicle 4 Download the configuration to the Vehicle Control Unit VCU 5 Rec...

Page 85: ... done The Read measure ment data dialog opens Click read data from logging device 11 Click on Settings tab and select the option Flash Card USB Stick Choose your DDU from dropdown list 12 Activate Apply changes Insert the USB device into the PC Data transmission from device starts automatically Measurement files are stored automatically in the base folder ...

Page 86: ...Start button and choose Open measurement file 15 Select the measurement files from the storage folder 16 Click on Open 17 Click in New Desktop to open a new measurement data window 18 Drag the desired measurement channel from the Channel list and drop it into the measurement data window The measurement channel s graph is displayed ...

Page 87: ...le the Vehicle Control Unit VCU is powered up or a different USB device is plugged in the Vehicle Control Unit VCU restarts In this case the Vehicle Control Unit VCU is not operational for 1 5 s 14 3 3 Troubleshooting When no data on the USB device is recorded Configure the measurement label usb_mediastate on a RaceCon measurement view or on a Vehicle Control Unit VCU display page The value of usb...

Page 88: ...ided that the up grade High speed logging has been activated on the device concerned Six analogue channels are available for high speed logging HS_ANA01 HS_ANA06 To set up the logging for high frequencies please consider the following hints The pin configuration pull up pin diagnosis is done like on any conventional pin Under I O channels the list of high speed channels appears and can be modified...

Page 89: ...ogged channels and drag and drop into the list the hs_ana_xx channel you want to be logged Attention This will only work if flat view is deactivated After double clicking the logging list entry you just created set the desired logging rate You will note that for hs_ana_xx channels logging frequencies of more than 1 kHz are available ...

Page 90: ...14 Recording 90 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport ...

Page 91: ...e consider this and replace the product name DDU 8 in this case with the name of your product 15 1 Error memory representation in RaceCon Bosch Motorsport devices feature an error memory Information on errors can be visual ized via RaceCon online measurement or can be transmitted via telemetry 15 1 1 Accessing the memory The error memory can be accessed as shown in the illustration ...

Page 92: ...or memory even after a power cycle The error state will then reflect if the error is still active or not An error is deleted from the list when the user actively clears the error memory the user updates the firmware The error memory is not cleared by a configuration download and is not cleared by a power cycle 15 1 2 Clearing the error memory There are two ways of clearing the error memory both ar...

Page 93: ...ed to be distinguished 15 2 1 Error Memory Properties The following property is available for the error memory itself Error Status device measurement label error_state 0 no error present in memory 1 at least one inactive error present in memory no active errors 2 at least one active error present in memory If displayed in a measurement sheet this property s value 0 1 or 2 is translated into a verb...

Page 94: ...lor scheme within RaceCon provided RaceCon is online with the system 0 no error present in memory No orange border MIL off black No entries 1 at least one inactive error present in memory no active errors Constantly orange border Info cycling through errors present in error memory MIL constantly orange ...

Page 95: ...rror_location_rotate e g ANA01 for an error concerning the first ANA channel Error durations How long has the error been active If an error encounters a non active period before being cleared from the memory and is then detected again the error duration keeps on accumulating The number of active periods can be seen from the number of oc currences Number of occurrences How many times has the error ...

Page 96: ... and represent the respective property of each error period ically The following screenshot shows error properties which can be displayed or logged Labels hold information on error 1 an ANA3 error Labels hold information on error 2 n 1 Labels hold information on error n a CAN error After the last error and its error properties have been displayed the labels will start again with the first error in...

Page 97: ...oring limits Shortcut Detection Cable Breakage The pin diagnosis functionality check whether measurement is within the desired range can be activated in the ANA pin setup wizard to allow for a diagnosis regarding shortcut to ground shortcut to battery voltage and cable breakage a minimum maximum has to be defined ...

Page 98: ...n consists of pull up resistors being activated and deactivated evaluating the behavior of the measured value detects cable breakage regardless of the pull up resistor being activated by the user 1 Open the Error Memory of the Device 2 Click start detection of cable 3 Check the Error Memory for new fault entries regarding Open line errors ...

Page 99: ...cost high precision limited reliability RF microwave based high precision high reliability IR and RF based Systems consists of Transmitter trackside unit Receiver in vehicle unit Lap Trigger Receiver Lap Trigger Transmitter 16 1 1 Electrical trigger signal In Vehicle Control Unit VCU all sources of measurement channels can be used as trigger signal Analog input Digital input CAN input Signal measu...

Page 100: ...nnected to the device and a detec tion point with a detection range has to be defined in RaceCon The GPS detection point is defined by the latitude and longitude The easiest way to get the latitude and longitude of a finishing line is due to a web mapping program such as google maps With google maps simply left klick on the spot where you want to set the detection point The information about the l...

Page 101: ...e occurring vehicle speed near the detection point 16 1 3 Prevention of false triggers Race track topology and transmitter location frequently cause false triggers Software functionality prevents acceptance of false triggers Minimum vehicle speed for acceptance of trigger prevents false triggers while vehicle is stationary in the pits Time based re trigger protection prevents false triggers due to...

Page 102: ...for the trigger signal Choose the source for the vehicle speed Enter the distance of the racetrack a b c d e f g h i j a Change signal device if desired b Change signal channel if desired c Choose signal threshold See chapter Electrical trigger signal for details d Define threshold of input channel signal when trigger is released Only possible if no digital source is selected as signal source ...

Page 103: ...trigger See chapter Segment timing for details j Define settings for a GPS lap trigger See chapter GPS lap trigger for details Only ap plicable if the signal source is set to GPS lap trigger Click Finish to complete the operation A pre configured lap trigger window opens Preset values for lap counter and outing counter Minimum laptime that a new best laptime is accepted Preset value for best lapti...

Page 104: ...e the detection range around the detection point Define the channel sources for Longitude Latitude Direction and Speed 16 1 6 Lap trigger channel diagnosis counter reset To display a quick lap trigger channel diagnosis and to reset counters use the diagnosis page in RaceCon Any Laptrigger_xxx channel can be displayed Double click on any Laptrigger_xxx channel in the Data Area Example laptrigger_la...

Page 105: ...o reset best lap time and distance based segmentation Lap trigger diagnosis scheme 16 1 7 Lap trigger presettings When the reset buttons on the diagnosis page are activated these values are used Preset values for lap counter and outing counter Minimum laptime that a new best laptime is accepted Preset value for best laptime 16 2 Counting outing laps fragments Functionality Power ON system measurem...

Page 106: ...MB time sec Channels for display To display counters use the following channels Channel Function Laptrigger_outcnt_dls Outing counter Laptrigger_lapctr_dls Lap counter Fractr Fragment counter Counting in WinDarab To automatically name recorded files use filename templates in WinDarab dialog Filename template Function outing Value of outing counter lap Value of lap counter fragment Value of fragmen...

Page 107: ...ved To deactivate time based retrigger protection set Retrigger lock time to 0 ms Define settings for lap timing main trigger Define settings for sub trigger Not applicable with a GPS lap trigger 5000ms Main Trigger 16 3 2 Distance based retrigger protection Trigger is locked until configured min distance i e 80 3200 m of track distance i e 4000 m has been covered To deactivate distance based retr...

Page 108: ...tween the max distance and the track distance i e 800 m To deactivate distance based forced triggers uncheck box Change signal for vehicle speed if desired Enter minimum speed for trigger release Define settings for distance based retrigger protection Define settings for distance based forced trigger 16 4 Segment timing Segment timing is the calculation of elapsed time for parts of laps segments S...

Page 109: ...ger 20 ms pulse at Start Finish Line 3 sub triggers 40 ms pulse posi tioned at 1 000 m 2 000 m and 3 000 m To deactivate sub trigger mode uncheck box Define settings for lap timing main trigger Define settings for sub trigger Not applicable with a GPS lap trigger Main Trigger Sub Trigger Sub Trigger Sub Trigger The sub trigger mode cannot be used with the GPS lap trigger 16 4 2 Distance mode Using...

Page 110: ... 2s 1000m 0 3s 0 1s 0 1s 16 5 Countdown timer Some race classes require a minimum time spent in the pits An additional lap trigger Tx is configured as a segment trigger positioned at pit entry The trigger signal starts a timer countdown The current value of the timer is stored in the variable Laptrigger_cntdown_dls which can be displayed Define settings for countdown timer ...

Page 111: ...the track length needs to be quite accurate within 100 m to adapt itself to another variant The known Racetrack list can be found in the lap trigger configuration menu within the Known Racetracks tab It contains a built in list and a user defined list Each track can be activated or deactivated with the checkbox to manually set the variant if needed User defined tracks can either be added from scra...

Page 112: ... name from the Racetracks list as an enumeration or can show the ID number as raw value The enu merated name will also be visible in the log ging Laptrigger_trackdet_laplen Track length of the used track variant Laptrigger_trackdet_lat Latitude GPS coordinate of the used GPS trigger point Laptrigger_trackdet_long Longitude GPS coordinate of the used GPS trigger point ...

Page 113: ... Control Unit VCU Configuration the configuration of Input channels CAN I O PWM display configuration recording telemetry configuration Calibration data Characteristic curves and offsets created by online calibration at the vehicle Recorded data Measurement data recorded during vehicle operation 17 2 Firmware update The scheme shows the process during each connection between RaceCon and Vehicle Co...

Page 114: ...he Vehicle Control Unit VCU Project Tree right click on Vehicle Control Unit VCU and choose Synchronize then Update firmware A pop up menu opens 2 Select the destination of the firmware archive PST You can find the latest firmware for the device at the Bosch Motorsport homepage 3 Click OK when done The firmware update starts The Vehicle Control Unit VCU dis plays the message Updating firmware Do n...

Page 115: ...Unit_VCU_Manual 115 136 When the firmware update is complete the Vehicle Control Unit VCU displays the message Updating firmware finished Do a powercycle Switch the car s ignition off and on again to cycle the power of the Vehicle Control Unit VCU ...

Page 116: ... is a 1 1 copy of a device This can be useful for copying specific data like sensor offset cal ibration to a spare unit for a specific car Creating a clone file 1 Open the Tools window and click on the Clone button in the Extras menu 2 Select Extract from the dropdown menu 3 Choose the hardware device which should be cloned 4 Define destination and filename 5 Click OK to start procedure ...

Page 117: ...trol_Unit_VCU_Manual 117 136 Applying a clone file to a device 1 Click Clone apply in Extras menu 2 Choose clone file 3 Click Ok Please remember that following properties are not stored into the clone Lifetime of device Serial number Upgrade features ...

Page 118: ...rface baud rate must match Vehicle Control Unit VCU interface baud rate Vehicle Control Unit VCU Baud rate can be set with the GPS_BAUDRATE character istic Data format Vehicle Control Unit VCU expects 8 data bits no parity bit 1 stop bit 8N1 19 2 Protocol Vehicle Control Unit VCU expects NMEA Protocol ASCII The following messages are decoded Message Function GGA GPS fix information GSA Overall sat...

Page 119: ...ilock free of charge Navilock offers a USB connec tion cable for the sensor In U Center click View Configuration View to start the configuration The follow ing 3 points have to be changed Transfer Rate Click on PRT Ports Change the baud rate to a fixed value this value needs to meet the setting of Race Con For a good signal quality we recommend 115 200 baud Click on Send to store the new setting i...

Page 120: ...Motorsport Satellite System Click on GNSS GNSS Config Set the ticks as shown in the following picture Click on Send to store the new setting in U Center As during configuration step 1 click on CFG Configuration Click on Send to save the new setting on the sensor ...

Page 121: ...etting in U Center As during configuration step 1 click on CFG Configuration Click on Send to save the new setting on the sensor NOTICE Sensor needs reception for visible signal It takes time to start the sensor 19 4 Measurement labels The decoded NMEA messages are copied to these Vehicle Control Unit VCU measurement labels Measurement label Function gps_PDOP Position Dilution Of Precision gps_HDO...

Page 122: ...g mode used for navigation 1 Fix not available 2 2D 3 3D These measurement labels are arrays where the indexed element points to the same satellite E g gps_info_satsigstrength 3 tells the receiving signal strength of satellite 3 Satellite 3 has the SAT ID given in gps_info_satid 3 Measurement label Function gps_info_satid Satellite PRN number gps_info_satinuse Used in position fix gps_info_satelev...

Page 123: ...rt up Does the GPS sensor view the sky Did the GPS sensor complete its initial start up procedure This may take up to 20 min A correct reception is indicated when gps_fix is showing 3D Fix GPS sensor values are frozen Does the sensor has lost its reception The old values will be kept if the reception is lost The gps_smask channel shows which NMEA sentence is received ...

Page 124: ...ion calculation and tank management 1 Select Measurement Sources in Toolbox 2 Drag Fuel element and drop it on the vehicle in System Overview Do not drop it on the Vehicle Control Unit VCU Drag Drop A fuel consumption wizard opens b a c d e f g a Change device for fuel calculation if desired b Enter tank capacity of vehicle c Choose calculation mode ...

Page 125: ...uel consumption of last lap completed using target lap consumption entered in the field Target lap consumption g Choose values to initiate a reset of fuel consumption if desired Manually using RaceCon On power down assuming that the tank is filled each time the ignition is turned off By signal source as input channel e g a switch connected to input pin Press Finish when done 20 2 Fuel consumption ...

Page 126: ...tion for current lap starting at 0 Fuel_fuellapold_dls Fuel consumption of last lap completed Fuel_laprem_dls Remaining laps with fuel in tank 20 3 Example Measurement label Function Fuel_fuelcons_dls Running fuel consumption starting at 0 Fuel_fuelrem_dls Remaining fuel in tank starting at tank capacity Fuel_fuellap_dls Fuel consumption for current lap starting at 0 Fuel_fuellapold_dls Fuel consu...

Page 127: ... distance Please enter those values into input field The values can also be copied and pasted to the input field from an excel sheet as a normal text In the inter mediate trigger you just need to set the expected time the driver takes to reach the seg ment trigger NOTICE Please note that the segment time and length is always measured from the start line or where the main lap trigger is set 21 2 Fu...

Page 128: ...8 Toggle WP RP F9 Start measurement CTRL F9 Start recording F10 or Alt Go to menu bar F11 Toggle display to fullscreen Race Mode F12 Enlarge main screen CTRL Tab Switch between opened windows Project Tree Plus at numeric pad or right cursor Expand selected node Minus at numeric pad or left cursor Close selected node Star at numeric pad Open all nodes DEL Delete seleted object Display page measurem...

Page 129: ...hereby declares that the products named below Name Vehicle Control Unit Type F02U V02 724 01 From the date of manufacture 01 09 2019 comply with the provisions of the EU directive mentioned in the following Machinery Directive 2006 42 EC Low Voltage Directive 2014 35 EU EMC Directive 2014 30 EU RoHS Directive 2011 65 EU Radio Equipment Directive 2014 53 EU ATEX Directive 2014 34 EU Pressure Equipm...

Page 130: ...s is not able to comply with all regulations for complete apparatus machines or installations from the outset The product may only be assessed with regard to its electrical mechanical and functional safety as well as to environ mental effects e g foreign bodies temperature humidity after it has been installed in the product intended for the final user After the product has been installed its EMC p...

Page 131: ...s any supplier of an article containing a substance of very high concern SVHC in a concentration above 0 1 w w has the duty to provide the recipient of the article with sufficient information to allow safe use of the article Our product contains SVHC Substance CAS Number Lead monoxide lead oxide 1317 36 8 Lead 7439 92 1 ...

Page 132: ...hicle_Control_Unit_VCU_Manual Bosch Motorsport 24 Disposal Hardware accessories and packaging should be sorted for recycling in an environment friendly manner Do not dispose of this electronic device in your household waste ...

Page 133: ...Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 133 136 ...

Page 134: ...134 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport ...

Page 135: ...Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 135 136 ...

Page 136: ...Bosch Engineering GmbH Motorsport Robert Bosch Allee 1 74232 Abstatt Germany www bosch motorsport com ...

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