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Related Manuals for Bozzio Joysteer
Summary of Contents for Bozzio Joysteer
- Page 1 Universal System Manual for Standard Industrial System a product of the company Bozzio AG Universal System Manual Standard Industrial System Universal_System_Manual_Standard_Industrial_System_3_V10-250422.docx Aarbergstrasse 5 2560 Nidau Switzerland Bozzio AG * joysteer® page 1 of 51...
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Page 2: Table Of Contents
Universal System Manual for Standard Industrial System Content GENERAL ........................4 DISCLAIMER ......................... 4 SYSTEM ......................... 5 What is joysteer® ......................5 System overview ......................5 System Architecture ..................... 6 System performance (KPI’s) ..................7 INSTALLATION OF MODULES ..................9 Steer Actuator Module (SA) .................. - Page 3 Universal System Manual for Standard Industrial System SYSTEM DIAGNOSTIC ....................39 Error Information on CAN ..................39 ANNEX 1: SYSTEM EVENT LIST AND TROUBLESHOOTING........40 DOCUMENT HISTORY ....................51 Bozzio AG * joysteer® page 3 of 51...
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Page 4: General
Override or Emergency-Stop switches, is mandatory while the joysteer system is running Disclaimer Bozzio AG refuses their product liability if one or more of the following facts are given: • Driving the system by users who do not possess an appropriate driving licence •... -
Page 5: System
Universal System Manual for Standard Industrial System System What is joysteer® joysteer® is a drive-by-wire system (fully electrical) for steer, brake and gas with a digital control interface (CAN-Bus). It’s designed as a retrofit product for road vehicles. joysteer® is a safety critical application and therefore the system is designed in a fully redundant implementation. -
Page 6: System Architecture
Universal System Manual for Standard Industrial System System Architecture Bozzio AG * joysteer® page 6 of 51... -
Page 7: System Performance (Kpi's)
~250mm/sec (no load) Est. Time Half Stroke 350ms (from 0 to 50mm) 736N per motor ➔ 1472N nominal and permanent Max force: Max stroke 98mm Latency: 80msec (from CPU command to start movement) Acceleration: Bozzio AG * joysteer® page 7 of 51... - Page 8 Emulates analogue gas signals (different types of) Emulates digital gas signals (SENT protocol and PWM) Latency time 40msec (from CPU to signal raise) Restriction Take-over to safety driver by applying the gas pedal is not possible Bozzio AG * joysteer® page 8 of 51...
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Page 9: Installation Of Modules
Important: The steering column adjustment mechanism (steering wheel position) must be securely locked! Moving the steering column position may cause the steering actuator mounting to fail (torque support fails). Step by step instruction for mounting of the steer actuator: Bozzio AG * joysteer® page 9 of 51... - Page 10 Don’t tighten the bolts yet strongly, the yoke must be still movable. Ensure that the full length of the thread is used, but that the screw does not extend beyond the rubber buffer. Use Loctite 243 Bozzio AG * joysteer® page 10 of 51...
- Page 11 Tighten the two fixing bolts of the angle brackets. Make sure that the fitting is free of play, otherwise repeat this step. Use Loctite 243 Apply a torque of 10Nm Bozzio AG * joysteer® page 11 of 51...
- Page 12 Refer to the vehicle specific manual for more detailed installation instructions. Important: Should the window for the airbag be located in another spot than “straight up”, then the central disc can be rotated. This offset must be adjusted with the SystemManager. Bozzio AG * joysteer® page 12 of 51...
- Page 13 Please contact the system provider if turning the steering wheel remains too heavy. Doublecheck all the cables and connectors. Double check if finally all screws are tightened with the required torque. Bozzio AG * joysteer® page 13 of 51...
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Page 14: Brake Actuator Module (Ba)
Important for the installation is, that the mechanical connection of the actuator to the pedal shaft is done on the right point (application of the force). The actuator must be installed in the vehicle interior. Bozzio AG * joysteer® page 14 of 51... - Page 15 Universal System Manual for Standard Industrial System Step by step instruction for mounting of the brake actuator (exemplary based in VW T6.1): Axis brake pedal Brake actuator Mounting support bracket Axis pedalbracket Pedal bracket Locking pin with circlip Bozzio AG * joysteer® page 15 of 51...
- Page 16 Note: Do not yet tighten the screws. Cut the dashboard as needed Note: Remove the purple OBD diagnose connector and mount it on an easy to reach location in the vehicle. Tighten it using a Tie-wrap. Bozzio AG * joysteer® page 16 of 51...
- Page 17 If not, to much friction is applied due to a misalignment and a readjustment is needed. Doublecheck all the cables and connectors. Double check if finally all screws are tightened with the required torque. Bozzio AG * joysteer® page 17 of 51...
- Page 18 Universal System Manual for Standard Industrial System Bozzio AG * joysteer® page 18 of 51...
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Page 19: Accelerator Module (Ac)
The acceleration function is not done with an actuator, but with a purely electronic module by emulation of the electrical pedal signals. If the joysteer system is OFF or in the JPAS/Manual-Override mode, the pedal values are used and conventional acceleration by operating the pedal is possible. - Page 20 Universal System Manual for Standard Industrial System Bozzio AG * joysteer® page 20 of 51...
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Page 21: Status Module (Stat)
The Status Module needs to be installed within sight of the user, as it provides visual (LED’s) and acoustic signals (buzzer) regarding the safety status of the joysteer® system. Because of the system redundancy, there are two LED’s and two buzzers integrated in the module. -
Page 22: Battery Module (Bat)
For mounting, the battery modules can be stacked and fixed with a belt (part of the delivery). It’s prohibited and dangerous to drill holes into the case of the battery for mounting. The batteries must be installed in the vehicle interior. Testing: Doublecheck the cables and connectors. Bozzio AG * joysteer® page 22 of 51... - Page 23 Universal System Manual for Standard Industrial System Bozzio AG * joysteer® page 23 of 51...
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Page 24: Cpu Modules (Cpu)
For mounting, the CPU Modules can be stacked. Assure, that heat dissipation trough the ground plate is given and don’t mount it back-to-back to the other CPU or any other joysteer Module. Bozzio AG * joysteer®... - Page 25 Universal System Manual for Standard Industrial System The CPU Modules must be installed in the vehicle interior. Testing: Doublecheck the cables and connectors. Bozzio AG * joysteer® page 25 of 51...
- Page 26 Universal System Manual for Standard Industrial System Bozzio AG * joysteer® page 26 of 51...
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Page 27: Motor Control Modules (Mc)
For mounting, the MC Modules can be stacked. Assure, that heat dissipation trough the ground plate is given and don’t mount it back-to-back to the other MC or any other joysteer Module. Bozzio AG * joysteer®... - Page 28 Universal System Manual for Standard Industrial System The module must be installed in the vehicle interior. Testing: Doublecheck the cables and connectors. Bozzio AG * joysteer® page 28 of 51...
- Page 29 Universal System Manual for Standard Industrial System Bozzio AG * joysteer® page 29 of 51...
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Page 30: Force Shutdown Pushbutton
Universal System Manual for Standard Industrial System Force Shutdown Pushbutton There is a “hidden” Pushbutton available giving the possibility to hard-reset the joysteer System in case it cannot be switched off anymore. This has only to be done by a service technician or remotely with an agreement of such. -
Page 31: Commissioning And Parametrisation
The CAN dongle is not needed for end customer installations but an rather an inventory item for the workshop. The CAN dongle can be used if you do not want to communicate via Bluetooth between the SystemManager and the joysteer 3.0 system. Software updates are faster and the connection is more stable. -
Page 32: Can Interface
Each of the two CPU Modules have one external control CAN interface (redundant interface, see the document “Wiring Diagram Standard Industrial System”). Parameter The CAN interface to the joysteer® system (Connector X104 on CPU Module) operates using the following pin assignment and parameter: CAN bit-rate: 500 kbit/s See file “Js3IndustrialStandard_Vx.x.x.dbc”... -
Page 33: Heartbeat Supervision
Error “Heartbeat error on external CAN” Reaction: Within the CAN frames sent by the joysteer® system, the heartbeat is increased by 1 every time a frame is sent. It is up to the vehicle control unit to supervise this heartbeat. -
Page 34: Degradation Concept
System Outage Doppelfehler aufgetreten Funktion(en) ausgefallen, Gas limitiert Betriebszustände joysteer 3.0 System It is up to the vehicle control unit to react to failures of CAN frames sent by the joysteer® system. Bozzio AG * joysteer® page 34 of 51... -
Page 35: Steering: System Behaviour In Case Of An Error
0% - 100% System behaviour on Position control mode. Setpoint source System State Target position used Leg A Leg B on CPU A on CPU B Operation Normal Bozzio AG * joysteer® page 35 of 51... -
Page 36: Gas: System Behaviour In Case Of An Error
0% - 100% Setpoint source System State Target gas value used Leg A Leg B on CPU A on CPU B Bozzio AG * joysteer® page 36 of 51... - Page 37 Operation Emergency ERROR Operation Failure Operation Emergency ERROR ERROR System Outage If an error is present at the same time on both legs, the system is set to the System Outage state. Bozzio AG * joysteer® page 37 of 51...
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Page 38: State Machine
Universal System Manual for Standard Industrial System State Machine The joysteer® system contains a state machine which can be controlled over the CAN interface. States and Transitions For description of the available states, transitions, and the functionality per state, see the document “State-Machine_Standard-Industrial-System”. -
Page 39: System Diagnostic
Universal System Manual for Standard Industrial System System Diagnostic The joysteer® system records occurred events. For a most detailed analysis of the occurred events its recommended to read the log by using the SystemManager. This way all available information is provided. -
Page 40: Annex 1: System Event List And Troubleshooting
The safe power supply has been initialized. The result shows if the initialization was successful. If this is not the case, there was a problem initializing the power supply and the module will not work. A module restart can solve the issue. Bozzio AG * joysteer® page 40 of 51... - Page 41 The internal module temperature has exceeded high limit and cooling should be improved. Check if the heating system of the car is not blowing hot air onto the module. Low board temperature The internal module temperature fell below low limit. Bozzio AG * joysteer® page 41 of 51...
- Page 42 A safety mechanism denies the enabling of the motor driver. Please contact your supplier. CAN communication disturbance CAN communication disturbance on CPU X103/X105. Please check that CAN termination resistor is connected to internal CAN. Bozzio AG * joysteer® page 42 of 51...
- Page 43 (e.g. Steering) is disabled on the CPU but the according HMI or actor is still connected. Data missing on external CAN A CAN frame on the external CAN bus (X104) has not been received for more than the implemented timeout. Please check your gateway. Bozzio AG * joysteer® page 43 of 51...
- Page 44 Battery Module supply failure The supply for the Battery Module (X102) has detected a failure. Check cabling. HMI supply output failure The supply for the HMIs (X103) has detected a failure. Check for cabling. Bozzio AG * joysteer® page 44 of 51...
- Page 45 The actuator mode for leg A and B (commanded by external CAN) is different. Please check your gateway. Battery Module: cannot discharge The Battery Module cannot be discharged. Please check battery cabling and contact your supplier if the error persists. Bozzio AG * joysteer® page 45 of 51...
- Page 46 HMI output (X103) can not be switched correctly. Please contact your supplier. ACT FET turn on error ACT output (X105) can not be switched correctly. Please contact your supplier. Inconsistent Degrade System has inconsistent degradation levels. Can be a result of another error. Bozzio AG * joysteer® page 46 of 51...
- Page 47 An interruption of the motor conductor was detected. Cabling or motor failure. Please exchange Motor Control Module if the error persists. Motor conductor interrupted An interruption of the motor conductor was detected. Cabling or motor failure. Please exchange Motor Control Module if the error persists. Bozzio AG * joysteer® page 47 of 51...
- Page 48 No data from car received Check if the cabling to the car CAN bus is interrupted. Unknown car gear The car reported a gear position which is not known. Please report this error to your supplier. Bozzio AG * joysteer® page 48 of 51...
- Page 49 Battery cell imbalance detected. Please contact your supplier. BMS communication error Battery internal communication problem. Please contact your supplier. Analog frontend booted Battery needed to reset BMS frontend. Can happen on first start after installation. Bozzio AG * joysteer® page 49 of 51...
- Page 50 Standard Industrial System Bozzio AG * joysteer® page 50 of 51...
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Page 51: Document History
Error 03.07.2024 Hem Updates Event List 03.07.2024 20.03.2025 27.02.2025 Update with System and Performance Data (hem) Update Annex 1 (Troubleshooting) and 26.03.2025 Hem mechanical guideline not to mount back-to- 22.04.2025 back Bozzio AG * joysteer® page 51 of 51...
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