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Bosch VCU Manual

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Vehicle Control Unit VCU
Manual
Version 1.3 02/07/2020

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  Summary of Contents for Bosch VCU

  • Page 1 Vehicle Control Unit VCU Manual Version 1.3 02/07/2020...
  • Page 2: Table Of Contents

    14.1 Features ............................................ 14.2 Configuration of Recordings.................................... 14.3 USB recording ........................................14.4 High speed logging ......................................15 Error Memory .................................. 15.1 Error memory representation in RaceCon ..............................15.2 Information on errors available from the error memory ........................ii / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 3 20.2 Fuel consumption diagnosis/counter reset..............................20.3 Example ............................................ 21 Predated Laptime................................21.1 Setting up the predated laptime ..................................21.2 Functionality and channel outputs ................................22 RaceCon Shortcuts................................23 Legal ....................................23.1 EC/EU Declaration of Conformity................................... 23.2 REACH Statement......................................... 24 Disposal.................................... Bosch Motorsport Vehicle_Control_Unit_VCU_Manual iii / 136...
  • Page 4: Preparation

    1 | Preparation 1 Preparation Use the Vehicle Control Unit VCU only as intended in this manual. Any maintenance or re- pair must be performed by authorized and qualified personnel approved by Bosch Motorsport. Operation of the Vehicle Control Unit VCU is only certified with the combinations and ac- cessories that are specified in this manual.
  • Page 5: Warnings And Safety Instructions

    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 source of danger Consequences Warning of damage to equipment in case of ignoring. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 5 / 136...
  • Page 6: Onboard Network Concept

    Be careful to observe current limits of wires and connector pins! IGN- Switch UBAT Star connection switched pos. terminal (term30) positive terminal Electric Loads Main KL15 Switch KL30 Bosch Motorsport Device diagnosis connector µC LS_SWITCH1…4 KL31 UBATT_FUSE GND_Starpoint SENSPWR10 Star connection Chassis dig. sensors (e.g. wheelspeed)
  • Page 7: Technical Data

    – Real time Ethernet SERCOS 3 – Event logging, Configurable pre-event logging The Vehicle Control Unit VCU is a highly powerful processing unit for customer-developed functions integrating a flexible logging device with high speed logging capability of up to 200 kHz.
  • Page 8 Internal measurement 1 ambient pressure 1 ECU temperature 20 supply voltage 20 supply current 1 battery voltage (external VCU supply) 1 external VCU supply current 4 HS output current Outputs PWM High side 2*; 7.5 A each, PWM, 50 Hz PWM Low side 4*;...
  • Page 9 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 involving data from different devices.
  • Page 10 4 | Technical Data 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) 10 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 11: Pinlayout

    LIFE 32 B_D_SERCOS2TXN LIFE 33 B_D_SERCOS2TXP LIFE 34 B_D_ETH3RXN LIFE 35 B_D_ETH3RXP LIFE 36 B_D_ETH3TXP LIFE 37 I_DIGIN03_HALL_DF11 0 to 5 V LIFE 38 BI_CAN6_H 0 to 5 V LIFE 39 BI_CAN6_L 0 to 5 V Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 11 / 136...
  • Page 12 GND, 2 A fused SENS-A 08 O_HSOUT3 VBAT / 8 A SENS-A 09 O_HSOUT3 VBAT / 8 A SENS-A 10 O_LSOUT5 VBAT / 2 A SENS-A 11 G_SENSGND08 GND, 2 A fused SENS-A 12 G_SENSGND07 GND, 2 A fused 12 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 13 0 to 5 V SENS-A 50 I_ANA24_20V 0 to 20 V SENS-A 51 I_LVDT4_SEC1P -5 to 5 V SENS-A 52 O_LVDT4_PRI1 -5 to 5 V SENS-A 53 I_LVDT3_SEC_M -5 to 5 V SENS-A 54 G_SCR_LVDT3 GND, 2 A fused Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 13 / 136...
  • Page 14 -5 to 5 V SENS-B 23 O_LVDT1_PRI2 -5 to 5 V SENS-B 24 I_LVDT1_SEC2N -5 to 5 V SENS-B 25 O_HSOUT1 VBAT / 8 A SENS-B 26 O_HSOUT1 VBAT / 8 A SENS-B 27 G_SENSGND11 GND, 2 A fused 14 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 15 0 to 5 V SENS-B 62 I_ANA04_5V 0 to 5 V SENS-B 63 I_ANA_HSL1 0 to 5 V SENS-B 64 I_ANA_HSL6 0 to 5 V SENS-B 65 I_ANA03_5V 0 to 5 V SENS-B 66 I_ANA_HSL3 0 to 5 V Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 15 / 136...
  • Page 16: Communication Channels

    6 Communication Channels CAN bus The Vehicle Control Unit VCU has two CAN buses configurable as input and output. Dif- ferent baud rates are selectable. Please note that the Vehicle Control Unit VCU does not contain any CAN termination resistors. Thus, the CAN termination resistors need to be in- tegrated into the wiring loom.
  • Page 17: Mechanical Drawing

    Mechanical Drawing | 7 7 Mechanical Drawing 86.6 YAW RATE SENSOR Drehratensensor 86.6 Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 17 / 136...
  • Page 18: Starting Up

    8 Starting Up 8.1 Before starting Install the software required Vehicle Control Unit VCU operation. It is developed for Win- dows system software. Following software versions are used in this manual: – Vehicle Control Unit VCU setup, configuration and calibration: RaceCon –...
  • Page 19 – 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 In the next step, the ECU needs to be specified. A pop up window appears, to specify the ECU program archive. Download the firmware for the Vehicle Control Unit VCU from www.bosch- motorsport.com. An information shows if the archive is valid or not.
  • Page 21 Select ‘Race track’ or ‘Testbench’ mode according to your application. Click ‘Finish’. 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.
  • Page 22 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.
  • Page 23: Feature Activation

    VCU does not work on any 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.
  • Page 24 Enter the activation key you received for this feature on this device and click ‘OK’ when done. The feature’s status changes to ‘unlocked’. Perform these steps to activate other features you purchased. Switch the car’s ignition off and on again to cycle the power of Vehicle Control Unit VCU. 24 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 25: First Recording (Quick Start)

    Drag + Drop 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 you can find the ‘ub’ measurement channel in the ‘Data Area’.
  • Page 26 As we did not define global start conditions, recording starts immediately. Start the WinDarab software. Disconnect the Vehicle Control Unit VCU network cable. Click on the ‘Read Data from Logging Device’ icon. Choose your logger and click ‘OK’ when done.
  • Page 27 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’.
  • Page 28: Set Time And Date

    The ‘ub’ measurement channel‘s graph is displayed. 8.4 Set time 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 &...
  • Page 29 A ‘Set Date & Time’ menu opens Set the current local date and time as coordinated universal time. At ‘Set a specific date & time’ click and type on the value you want to change, or choose from the dropdown menu. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 29 / 136...
  • Page 30: Project Configuration

    Enter the formula. d) Select the logical operator. e) Choose a measurement channel. f) Define a value that can be used as a constant in the formula. g) Choose a function. h) Describes the function selected above. 30 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 31: Conditional Functions

    Project Configuration | 9 Click ‘Finish’ when done. The math channel is displayed in the Vehicle Control Unit VCU math channel window. 9.2 Conditional Functions – Arithmetic and logical operations on one or more measurement channel(s) – If-Else structure with reset –...
  • Page 32 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: Setting up a condition for maximum front brake pressure Brake pressure front p_br_front Brake pressure ‘front p_br_front’...
  • Page 33: Conditional Channels

    – Result can be used as input source for alarm display elements and further calculations in the whole RaceCon project. Creating a new Conditional Channel Follow the steps shown in the screenshot. The “Create/edit condition” window appears. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 33 / 136...
  • Page 34: Condition Combination

    – Toggling output: Result is a pulse that lasts until the next condition is fulfilled. – Click ‘Ok’ when done. The conditional channel is displayed in the Vehicle Control Unit VCU condition channel window. 9.4 Condition Combination – Combination of several (up to 16) conditional channels for more complex calculations –...
  • Page 35 Project Configuration | 9 – All conditions can be used globally in the whole Vehicle Control Unit VCU project. Creating a new Condition Combination Follow the steps shown in the screenshot. The ”Create/edit condition combination” window appears. Define the condition combina- tion, using the following configuration possibilities: a) Enter the name of the condition combination.
  • Page 36: Cpu Load Limits

    – 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 entry. To trigger this error entry, the CPU load must exceed the limit for 5 minutes without interruption.
  • Page 37: Can Configuration

    CAN Configuration | 10 10 CAN Configuration The Vehicle Control Unit VCU has 4 (plus 4 on request) fully configurable CAN bus(es). – Baudrate 125 kbaud to 1 Mbaud – 11 Bit or 29 Bit identifiers – Input configuration: Read messages from CAN bus and convert to Vehicle Control Unit VCU measurement/display variables.
  • Page 38: Can Input

    10.2.2 Create new CAN Input channel Double-click on any CAN bus item, to open the "CAN messages overview". Select ‘Add CAN-IN’ and choose the desired CAN bus for the new input channel. A CAN channel configuration window opens. 38 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 39 CAN Configuration | 10 Insert the name and description of the channel. Click ‘OK’ when done. The channel is listed in the Data window. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 39 / 136...
  • Page 40 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. 40 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 41 Enter offset for conversion to physical value. c) Select type of physical value. d) Select unit of physical value. e) Enter minimum physical limit of the channel. (for manual setup) f) Enter maximum physical limit of the channel. (for manual setup) Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 41 / 136...
  • Page 42 This functionality is only available, if a MSA-Box (I or II) is used to connect the Vehicle Control Unit VCU to the PC. Choose the CAN bus that is connected to the MSA-Box to display the raw value and the converted physical value here.
  • Page 43 10.2.5 Import a CAN database (DBC) file Right-click on CAN Input of desired bus (CAN1 or CAN2). Select ‘Import DBC file’ from menu. A file browser opens. Select DBC file to import and click ‘OK’ when done. A channel import window opens. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 43 / 136...
  • Page 44: Can Output

    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 new output channel. 44 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 45 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. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 45 / 136...
  • Page 46: Multiplexer

    – Re-use (multiplex) of message identifiers by splitting it into several rows. – Every row is assigned to a unique value of the multiplexer. – One byte of message contains row counter. 46 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 47 Select a channel and configure it. To assign it to the row selected before, check the box ‘Multiplexed’. To move the channel message, change the “Start” value or click and hold the green field in the “Add new CAN out message” window. Click ‘OK’ when done. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 47 / 136...
  • Page 48 10 | CAN Configuration 10. The channel message is assigned to the selected fields. 11. Click ‘OK’ when done. 48 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 49: Analog And Frequency Inputs

    Filtered physical value Filtered channels are routed through digital low pass filters: – Vehicle Control Unit VCU uses A/D converter oversampling and digital filtering to re- cording rate – Digital filters eliminate ‘out-of-band’ noise – Cut-off frequency automatically adjusted to recording rate –...
  • Page 50: Configuring Inputs

    'Bosch Sensor Wizard' Click on ‘Measurement Sources’ in the Toolbox. To expand the list of ‘I/O Channels’, click on ‘+’ in the Vehicle Control Unit VCU Pro- ject Tree. 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.
  • Page 51 Click ‘Finish’ when done. The “Create channel” window opens. Enter the channel name and description. Click ‘Ok’ when done. The channel is inserted into the Vehicle Control Unit VCU Project Tree. Channel is linked to ANA03 Calculation of physical value with...
  • Page 52 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 use a push-button. The fixed value of the internal pullup-resistor is 3,010 Ohm.
  • Page 53 ‘Setting up an online measurement [} 70]’. Click ‘Finish’ when done. Enter a channel name and a description. Click ‘OK’ when done. The channel is inserted into the Vehicle Control Unit VCU Project Tree. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 53 / 136...
  • Page 54 3 kOhm Thermistor Click ‘Measurement Sources’ in the Toolbox. To expand the list of ‘I/O Channels’, click on ‘+’ in the Vehicle Control Unit VCU Pro- ject Tree. Drag the “Characteristic Curve” analogue signal source from the Toolbox and drop it on the desired analogue input channel in the Vehicle Control Unit VCU Project Tree.
  • Page 55 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.
  • Page 56 Click ‘Finish’ when done. Enter channel name and description. Click ‘OK’ when done. The channel is inserted into the Vehicle Control Unit VCU Project Tree. Channel is linked to ANA05 Characteristic Adjustment curve for sensor...
  • Page 57 – Curve definition by online adjustment at vehicle Click on ‘Measurement Sources’ in the Toolbox. Expand the list of ‘I/O Channels’ by clicking on ‘+’ in the Vehicle Control Unit VCU Project Tree. Drag the ‘Multipoint Adjustment’ analog signal source from the Toolbox and drop it on the desired analog input channel in Vehicle Control Unit VCU Project Tree.
  • Page 58 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 use a push-button. The fixed value of the internal pullup-resistor is 3.01 kOhm.
  • Page 59 Click ‘Finish’ when done. Enter channel name and description. Click ‘OK’ when done. The channel is inserted into the Vehicle Control Unit VCU Project Tree. Channel is linked to ANA06 Characteristic Adjustment curve for sensor...
  • Page 60 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...
  • Page 61 – Each passing tooth of pulse wheel triggers hall sensor – Calculation of wheel speed with wheel circumference Click on ‘Measurement Sources’ in the Toolbox. To expand the list of ‘I/O Channels’, click on the ‘+’ in the Vehicle Control Unit VCU Project Tree. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 61 / 136...
  • Page 62 11 | Analog and Frequency Inputs Drag the ‘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. Select the sensor type. The DDU10 works with Halleffect and DF11 sensors.
  • Page 63 Click ‘Finish’ when done. Enter the channel name and description. Click ‘OK’ when done. The channel is inserted into the Vehicle Control Unit VCU Project Tree. Channel is linked to REV01 Input pin Number of...
  • Page 64: Configuring Computed Sources

    Example: Sensitivity/offset calculation on input channel Click ‘Measurement Sources’ in the Toolbox. 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.
  • Page 65: Hysteresis

    Click ‘Finish’ when done. Enter channel name and description. Click ‘OK’ when done. The channel is inserted into the Vehicle Control Unit VCU Project Tree. NOTICE Working with automatically created measurement sheets is ex- plained in chapter ‘Setting up an online measurement’.
  • Page 66 Enter name to automatically create a new measurement sheet Click ‘Finish’ when done. Enter channel name and description. Click ‘OK’ when done. The channel is inserted into the Vehicle Control Unit VCU Project Tree. Channels available in Computed sources Calculation of hysteresis channel...
  • Page 67 Click on ‘Measurement Sources’ in the Toolbox. 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’...
  • Page 68 11 | Analog and Frequency Inputs Speed calculation in DDU Project Tree Measurement channels calculated speed and calculated distance Configuration window 68 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 69: Power Stages

    Power Stages | 12 12 Power Stages Power stage details The Vehicle Control Unit VCU uses integrated power stages with built-in diagnosis. For the high side switches, overload-behaviour (mode “bulb” or “DC motor”, restarts etc.) is de- termined inside the IC itself.
  • Page 70: 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. Expand ‘Measurement Container’ and ‘Measurement Folder 1’ in the Project Tree and double-click on ‘Sheet1’. Alternatively, click on the ‘Calibration/Measuring’ tab to open the window directly.
  • Page 71 To add an element to a measurement sheet, perform the following steps: Drag a measurement element from the Toolbox and drop it on the measurement sheet. Drag + Drop Select the desired measurement channel from the ‘Data’ area and drop it on the measurement element. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 71 / 136...
  • Page 72 Numeric indicator 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 RaceCon. 72 / 136 Vehicle_Control_Unit_VCU_Manual...
  • Page 73 Drag + Drop 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 Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 73 / 136...
  • Page 74 13 | Online Measurement and Calibration To create the sheets, right-click on Vehicle Control Unit VCU and select ‘Create meas- urement views…’ from the Vehicle Control Unit VCU context menu. Click to create measurement sheets The automatically created sheet is inserted in the Project Tree under ‘Measurement Container’...
  • Page 75: 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 Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 75 / 136...
  • Page 76 13.2.2 Performing the online offset calibration Vehicle Control Unit VCU has to be connected to RaceCon to calibrate the sensor’s offset. Apply the desired physical condition to the sensor (e.g. 1 G to an acceleration sensor). Open the measurement channel’s online page by double-clicking on the measure- ment channel name in the Data Area.
  • Page 77: Online Calibration Of Multipoint Adjustment Channels

    Create a multipoint adjustment measurement channel. To create a multipoint channel, see chapter ‘Configuring a multipoint adjustment [} 57]’. 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’.
  • Page 78 13 | Online Measurement and Calibration Press the ‘Calibrate’ button of the desired calibration point. Repeat for all curve points. 10. Click ‘Close’ when done. The calibration curve is displayed in the online view. Adjustment points vs. offset adjustment 78 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 79: Recording

    – Up to 16 measurement conditions (fast-slow-switches) 14.2 Configuration of Recordings Expand the ‘Logger’ list by clicking on ‘+’ in the Vehicle Control Unit VCU Project Tree. Double-click on ‘Logging’ in the Vehicle Control Unit VCU Project Tree. The recording configuration is displayed in the Main Area.
  • Page 80 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 To edit channel settings, mark the channel(s) and click ‘Edit Recording Channel(s)’. 80 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 81 The ‘Logger’ window opens. Click on the ‘Add’ button. A new group will be added and can be renamed ‘Gearbox’, ‘Aero’, ‘Engine’, etc.. To rename a group, click on the ‘Rename’ button next to the ‘Add’ button. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 81 / 136...
  • Page 82 14 | Recording 14.2.2 Logger settings To display the global Vehicle Control Unit VCU settings, open the ‘Logger’ window and click on the ‘Settings’ tab at the bottom. a) Choose setting for outing counter mode: – For testbench (without lap trigger) select ‘Testbench’.
  • Page 83: Usb Recording

    0, a red highlighted channel means 1. – Measurement correctly initialized, but 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...
  • Page 84 Storage device The recording function can be used with a dedicated Bosch Motorsport USB device. The USB device has to be preformatted with the Bosch File System (BFS) in RaceCon before first use. To format the USB device with the Bosch File System (BFS), do the following steps: In RaceCon, select ‘Tools’...
  • Page 85 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. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 85 / 136...
  • Page 86 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 86 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 87 If the USB device is unplugged and re-inserted for > 4 s while 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.
  • Page 88: High Speed Logging

    (Hint: Re-format the USB device in RaceCon.) 14.4 High speed logging The VCU can acquire analogue channels at a rate of up to 200 kHz, provided that the up- grade “High speed logging” has been activated on the device concerned.
  • Page 89 “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. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 89 / 136...
  • Page 90 14 | Recording 90 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 91: Error Memory

    DDU 8. Please 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...
  • Page 92 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 are shown in the following illustra- tion: 92 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 93: Information On Errors Available From The Error 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 verbal description: Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 93 / 136...
  • Page 94 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 MIL constantly orange Info cycling through errors, present in error memory 94 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 95 All failure modes are continuously diagnosed; any error detected will be written to the error memory. Once an error is detected, it is qualified as “active”. – 1 (TRUE) Error was detected in most recent diagnose run (active) Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 95 / 136...
  • Page 96 (while more than one error is active) and watch the values change periodically: The verbal representation of the numerical codes of these labels can be visualized in the properties window of the measurement page: 96 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 97: Analog Input Diagnosis

    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. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 97 / 136...
  • Page 98 Open the Error Memory of the Device. Click "start detection of cable". Check the Error Memory for new fault entries, regarding "Open line errors". 98 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 99: Lap Trigger

    – Receiver (in-vehicle unit) Lap Trigger Transmitter Lap Trigger Receiver 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 (measurement channel) properties Low active signal (Bosch triggers): Trigger releases if signal is below the threshold.
  • Page 100 – Main trigger (end‐of‐lap at start/finish line) – Sub‐trigger (segment time, optional, not applicable with GPS lap trigger) Bosch standard: – Main trigger 20 ms, low active (Recommendation for RaceCon “Detecion Time” set- ting: 15 ms, Setting must be a slightly shorter period than the signal length of the trigger to avoid a missed trigger due to the update rate) –...
  • Page 101 Under race conditions, trigger signals are sometimes missed. Software functionality intro- duces ‘forced trigger’. 16.1.5 Setting up a lap trigger Click ‘Measurement Sources’ in Toolbox. Drag ‘Laptrigger’ into ‘System Overview’. Do not drop it on ‘Vehicle Control Unit VCU’! Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 101 / 136...
  • Page 102 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. 102 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 103 Enter minimum speed for trigger release. Define settings for distance based retrigger protection. Define settings for distance based forced trigger. Define settings for lap timing (main trigger). Define settings for sub trigger. Not applicable with a GPS lap trigger. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 103 / 136...
  • Page 104 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_lap- dist_dls’ A diagnosis window opens in Main Area. 104 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 105: Counting Outing/Laps/Fragments

    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 + measurement is initialized but not yet started Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 105 / 136...
  • Page 106: Lap Timing

    The detection time defines the minimum time the input signal changes its state. E.g. a low active signal needs to be below the threshold for min. 15 ms to release the trigger. Channels for display To display lap times use the following channels: Channel Function Laptrigger_lapctr_dls Number of completed laps 106 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 107 4000 m) has been covered. To deactivate distance based retrigger protection, set min dis- tance to 0 %. 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. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 107 / 136...
  • Page 108: Segment Timing

    Segment timing is the calculation of elapsed time for parts of laps (segments). Segments are defined: – based on sub-trigger signals (additional transmitters) – based on distance travelled Times for segments are compared to: – Last lap completed – Fastest lap 108 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 109 Set ‘Mode’ to ‘Distance’ and enter desired segment distances. Segment time is automatically calculated at each segment. Time difference to last lap and fastest lap is automatically calculated at each segment. To deactivate distance mode set ‘Mode’ to ‘None’. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 109 / 136...
  • Page 110: Countdown Timer

    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. 110 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 111: Automatic Gps Track Detection

    GPS tab with the button “Set values …”. This allows an easy interaction with the manual GPS lap trigger mode. The user-defined tracks will be part of the project. If the tracks are required in another project, the lap trigger module can be ex-/imported into another project. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 111 / 136...
  • Page 112 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 112 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 113: Firmware

    17.1 Firmware and configuration Vehicle Control Unit VCU holds 4 types of data: Firmware: the software (PST program file) of the Vehicle Control Unit VCU. Configuration: the configuration of Input channels, CAN I/O, PWM, display configuration, recording + telemetry configuration.
  • Page 114 17 | Firmware 17.2.1 Performing the firmware update Firmware update is only possible if the Vehicle Control Unit VCU is connected to RaceCon. The configuration of Input channels, CAN I/O, display, recording + telemetry will not be changed. In the Vehicle Control Unit VCU Project Tree, right-click on ‘Vehicle Control Unit VCU’...
  • Page 115 Firmware | 17 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: Cloning The Unit

    18 Cloning the Unit To replace a Vehicle Control Unit VCU by another device, it is possible to clone it. A clone 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.
  • Page 117 Applying a clone file to a device Click ‘Clone apply’ in Extras menu. Choose clone file. Click ‘Ok’. Please remember that following properties are not stored into the clone: – Lifetime of device – Serial number – Upgrade features Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 117 / 136...
  • Page 118: Gps Sensor

    GPS Rx interface 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...
  • Page 119 Con. For a good signal quality we recommend 115,200 baud. – Click on “Send” to store the new setting in “U-Center”. – Click on “CFG (Configuration)”. – Click on “Send” to save the new setting on the sensor. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 119 / 136...
  • Page 120 – 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. 120 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 121: Measurement Labels

    – 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...
  • Page 122: Gps Troubleshooting

    Does the GPS sensor deliver RS232 signal levels? Is the sensor connected to the „sensor ground“ of the device? Interface Do the baud rates of the GPS sensor and the Vehicle Control Unit VCU match? Is the GPS sensor set up for 8N1 transmission parameters? 122 / 136...
  • Page 123 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. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 123 / 136...
  • Page 124: Fuel Consumption Calculation

    Select ‘Measurement Sources’ in Toolbox. 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. a) Change device for fuel calculation, if desired.
  • Page 125: Fuel Consumption Diagnosis/Counter Reset

    Double-click on any ‘fuel_xxx’ channel in channel list. A diagnosis window opens in Main Area. Button to reset total fuel consumption (Reset with RaceCon only) Button to reset fuel consumption manually (Can also be triggered ) Settings overview Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 125 / 136...
  • Page 126: Example

    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 consumption of last lap completed Fuel_laprem_dls Remaining laps with fuel in tank 126 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • Page 127: Predated Laptime

    The channel Laptrigger_lapdiff_pred_dls is updated as soon as the main lap trigger is re- ceived. Both other channels are updated as soon as the next segment distance is travelled or the next intermediate trigger is received. Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 127 / 136...
  • Page 128: Racecon Shortcuts

    22 | RaceCon Shortcuts 22 RaceCon Shortcuts The table shows important shortcuts simplify controlling the Vehicle Control Unit VCU in RaceCon. Shortcut Function General navigation Open RaceCon help Rename selected object Select Data Area Select Project Tree Start the data comparison...
  • Page 129: Legal

    The content of the EC declaration of conformity is subject to modifications. Currently valid edition upon request. Bosch Engineering GmbH, Sitz: Registered Office: Abstatt, Registration Court: Amtsgericht Stuttgart HRB 746374 Chairman of the Supervisory Board: Dr. Rudolf Maier; Managing Directors: Dr. Johannes-Jörg Rüger, Dr. Frank Schmidt, Dr. Peter von Wartenberg...
  • Page 130 The content of the EC declaration of conformity is subject to modifications. Currently valid edition upon request. Bosch Engineering GmbH, Sitz: Registered Office: Abstatt, Registration Court: Amtsgericht Stuttgart HRB 746374 Chairman of the Supervisory Board: Dr. Rudolf Maier; Managing Directors: Dr. Johannes-Jörg Rüger, Dr. Frank Schmidt, Dr. Peter von Wartenberg 130 / 136...
  • Page 131: Reach Statement

    (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 Bosch Motorsport Vehicle_Control_Unit_VCU_Manual 131 / 136...
  • Page 132: Disposal

    24 | Disposal 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. 132 / 136 Vehicle_Control_Unit_VCU_Manual Bosch Motorsport...
  • 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...