Robert Bosch ACC2SCU Installer Instructions

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Technical Customer Information

ACC Distance Control Radar 2nd Generation

Ambience Conditions and Mechanics

0 265 K60 059

AE-DA/ELR

AE-DA/EFS

AE-DA/EPS

Issue and Author: 8

Department: Date: Signature:

Customer

Vehicle type

Order number

Offer drawing

System

Remark

General Information

ACC 2 Radar-Sensor

For I N F O R M A T I O N only

AE-DA/ELR4 26.11.03 Gez. Beez

Detailed description of modifications see page 2

Checked, Reviewed by:

Department: Date: Signature:

AE-DA/ELR4 26.11.03 Gez. Beez

Agreements, Permission by:

Department: Date: Signature:

AE-DA/ELR

AE-DA/EFS

AE-DA/EPS

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Page 2

ACC Distance Control Radar 2nd Generation

Modifications

Reviser

20.11.03

Technical Customer Information

Ambience Conditions and Mechanics

0 265 K60 059

No. Date/

04.07.01 - Preliminary Edition

1 08.08.01 -

2 24.01.02 watermark

3 05.02.02Bz3.1

4 27.05.02Bz1.3

Chapter Description of modification

Document Number

2.1

2.2

3.1

4.2

4.3 5

Mounting Conditions

new department names update of: drawings, outline dimensions, circuitry

drawing of outline dimensions update electrical data, circuits new chapter added for CAN communication specifications temperature after painting increased

operating temperature range adapted weight added clearance updated for bracket needs type of plug (MQS System from AMP) added fusing for V Bat an load dump protection added upper temperature adapted according chapter 2.1

5 12.08.02Bz2.1

3.1

6 24.01.03

Bz, Kl

7 27.08.03

20.11.03 Hil

8 12.01.04

Hil

Issue Date 30.01.03

1.4 FCC Part 15/RSS-210 wording for manual

Dep.:

Operating Temperature Range, max. temp. increased Bracket Concept added Cover Sheet updated chap. 2.1: operating temperature range adapted

chap. 2.2: climate conditions updated chap. 3: mounting conditions updated (clearance, cone of the radar beam, offer drawing) chap. 3.2: sensor adjustment directly from the front

offer drawing, figures, cone, sensor mounting

information of the scraping of the DUT

Information for radome material

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Technical Customer Information

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Ambience Conditions and Mechanics

Table of contents

1 EXTERNAL REFERENCE DOCUMENTS...............................................................................................4

1.1 E

1.2 R

1.3 C

1.3 U

NVIRONMENTAL TEST SPECIFICATIONS EGULATIONS OMMUNICATIONS

SER MANUAL

......................................................................................................................................... 4

..................................................................................................................................4

........................................................................................................................................ 5

................................................................................................... 4

2 AMBIENT CONDITIONS ..........................................................................................................................6

2.1 T

2.2 M

EMPERATURE RANGE

ECHANICAL AND CLIMATE CONDITIONS

............................................................................................................................. 6

.................................................................................................. 6

3 MOUNTING CONDITIONS.......................................................................................................................7

3.1 I

3.2 S

NSTALLATION INSTRUCTIONS FOR THE

ENSOR BRACKET / ADJUSTMENT

........................................................................................................... 10

ACC2 - SCU................................................................................ 7

4 ELECTRICAL DATA............................................................................................................................... 14

4.1 B

4.2 P

4.3 V B

4.4 CAN - I

4.5 O

4.6 O

4.7 O

4.8 O

4.9 O

LOCK DIAGRAM (TOP LEVEL

INNING AND TYPE OF CONNECTOR

- I

NTERFACE

NTERFACES PTIONAL DIAGNOSIS INTERFACE PTIONAL WAKE UP LINE PTIONAL RADOME HEATING LINE PTIONAL LENS HEATING LINE PTIONAL TIME GAP INPUT

............................................................................................................................... 16

............................................................................................................................... 17

) ............................................................................................................... 14

(WAU) ......................................................................................................... 21

.............................................................................................................. 23

(TGAP)...................................................................................................... 25

....................................................................................................... 15

(K-L

INE

)............................................................................................ 20

(RADOME)..................................................................................... 22

5 ENVIRONMENTAL TESTS..................................................................................................................... 26

6 EMC........................................................................................................................................................... 25

6.1 V

6.2 B

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EHICLE TESTS

ENCH TESTS

..................................................................................................................................... 25

........................................................................................................................................ 26

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Ambience Conditions and Mechanics

1 External Reference Documents

1.1 Environmental Test Specifications

The environmental tests for the ACC SCU are proceeded according:

DIN IEC 68-x-x DIN 50018 DIN 50021 DIN 40050, part 9 Bosch N42 AP xxx

1.2 Regulations

The ACC SCU meets the following statutory requirements and therefore obtains the type approvals from those countries mentioned in the requirements:

EN301091 V1.1.1 Code of Federal Regulation Part 15 Title 47 (FCC) RSS -210 Industry Canada Japanese ARIB STD-48 Radio-Communications(LIPD) Class Licence 2000 (Australia)

Type approvals from other countries than these from the regulations above can be achieved but have to be charged separately.

1.3 Communications

The ACC SCU meets the following specifications for CAN communication (high speed CAN):

SAE J 22284 ES-XS4T-12K259-Cx others

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Technical Customer Information

ACC Distance Control Radar 2nd Generation

Ambience Conditions and Mechanics

1.4 Wording for User Manual

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The user manual shall contain the following statements

This device complies with Part 15 of the FCC Rules and with RSS-210 of Industry Canada.

Operation is subject to the following two conditions:

(1) this device my not cause harmful interference, and (2) this device must accept any interference received, including interference that may

cause undesired operation.

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is

connected.

• Consult the dealer or an experienced radio/TV technician for help.

This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with minimum distance 20cm between the radiator and your body.

Warning: Changes or modifications made to this equipment not expressly approved by ROBERT BOSCH GmbH may void the FCC authorization to operate this equipment.

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Technical Customer Information

ACC Distance Control Radar 2nd Generation

Ambience Conditions and Mechanics

2 Ambient Conditions

2.1 Temperature range

Storage temperature - 20..+ 50 °C max 5 years

Operating temperature range (measured at ACC base plate) Temperature after painting + 125 °C max. 1h, non powered Temperature range for alignment (measured at ACC base plate)

2.2 Mechanical and climate conditions

- 40..+ 90 °C (short time 100°C)

- 10..+ 100 °C

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Mounting area Vehicle front area Kind of protection complete ACC-SCU IP 54 K (DIN 40 050)

frontal area (lens) IP X4 K (DIN 40 050)

IP X6 K (DIN 40 050) IP X9 K (DIN 40 050)

Stone impact frontal area (lens) Resistance to stone impact acording

VDA 621-427

Vibration Random vibration a

= 27,8 m/s2, 3x8 h

eff

(according ISO/DIS 16750-3)

Weight without bracket < 300g

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Ambience Conditions and Mechanics

3 Mounting conditions

3.1 Installation instructions for the ACC2 - SCU

The ACC SCU is installed in the frontal area of the vehicle. The sensor lens points in the vehicle driving direction, the connector either down to the road or up. The outline dimensions of the sensor are shown in the following drawing:

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Ambience Conditions and Mechanics

Ideally the sensor is to be integrated into the front-end without a cover in front of its lens. If the sensor is to be installed behind a cover or a radome, special care must be taken in

selecting the cover-material, cover shape (or design) and position of the cover relatively to the sensor. Water droplets and snow sticking onto the cover surface might cause additional attenuation that leads to a restricted performance or availability of ACC. For the uncovered build-in configuration the lens design of the ACC-SCU is chosen to minimise these effects. Water droplets can be blown off by the driving wind and sticking snow can be heated off by the integrated lens heating.

The following table lists the basic demands to the integration of the sensor into a front-end

of the car: Installation height above ground (roadway) Horizontal offset relative to the vehicle longitudinal axis

Horizontal angle relative to the vehicle longitudinal axis

Vertical tilt relative to the vehicle longitudinal axis

1 1

(dependent on pitch when car is fully loaded or while braking) Clearance of parts (out of metal or even plastic) in front of the

sensor can be described by a cone directly in front of the lens with the following angles

horizontal

vertical The cone that represents the radar beam in shown in figure 1 Clearance to other vehicle parts:

(sensor-movement during adjustment: ± 3° vertical and horizontal

and additional space for the bracket behind the SCU is considered)

in lateral direction

in front of the lens

behind the sensor (space for clip and bracket) Permissible attenuation caused by cover (bumper, radome) in front of the lens ; two-way (radar) loss The constraints for the cover are:

- homogeneous material has to be favourized

- non perpendicular orientated relatively to sensor radar axis

- favoured materials : see following material list

The material in front of the radar should not degrade the antenna parameters

• Beamwidth error

• Sidelobe change

• Peak boresight error

In case of radome heating the orientation of wire structures has to be checked Wire diameter is limited to max. 0.25mm

min. 300 mm max. 1000 mm max. 500 mm

0° Proposal: adjusting

area at sensor ± 3°

± 14°

± 7°

each side 10 mm 15 mm 30 mm

max . 1 dB

Minimise material thickness due to dielectric loss

• max. 1%

• max. 1 dB

• max. 0.1°

linear 45° from upper left to lower right as seen in

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Ambience Conditions and Mechanics

driving direction In case of shaped radome / bumper the radius of the material is limited In case of non-homogeneous material the air gap between the materials is limited In case of painting carbon based primer is not allowed

relative to the ACC SCU; central axis of the lens

the full adjustment range is only available at 0° vertical tilt

angle results from horizontal beam width (±8°) of the radar beam plus adjustment area

(±3°) plus safety margin (±3°). Car tolerances wont be considered.

angle results from vertical beam width (±3°) of the radar beam plus adjustment (±3°)

area plus safety margin (±1°). Car tolerances wont be considered.

Radome / Bumper Material list:

> 25 mm

< 0.05mm



tan  x 10

Material

Polyethenimid PEI 3.05 150 Polycarbonat PC 2.7 100 Polyethylene PE 2.3 5 Polypropylene PP 2.18 7 Polytetrafluorethylene PTFE 2.07 5.5 Polymethylenmetacrylat PMMA 2.62 26

-4

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Figure 1: Sketch of the area of clearance directly in front of the sensor (cone for representing the radar beam)

cone with elliptical shape: vertical ±7°

horizontal ±14°

Diameter of cone: 65 mm

Figure 2: Sketch of the bracket concept for the SCU

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ACC Distance Control Radar 2nd Generation

Bracket (metal)

Adjustment

adjustment

Adjustment

screw

for vertical

Technical Customer Information

Ambience Conditions and Mechanics

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screw for horizontal adjustment

Plastic Clip

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3.2 Sensor bracket / adjustment

The ACC SCU has to be fixed with a vehicle-specific sensor bracket. The bracket is used to attach the sensor to the vehicle. The points where the bracket is attached to the vehicle must be selected carefully to ensure a very stable mounting of the sensor relatively to the vehicle longitudinal axis.

The three clips are used to fix the sensor in the bracket. First each clip is locked by 90° rotation (clockwise). The sensor is fitted to the bracket by pressing the sensor with guiding the clip hole (see figure 2 above).

Please note that the bracket needs some space in the near surrounding of the sensor. The overall dimensions of the sensor with bracket have to be discussed together with the customer.

Mounting conditions min. 2 fixing points at the vehicle

no relative movement between the fixing points at the vehicle long-term stability between the fixing points and relative

to the vehicle longitudinal axis max torque for clip (locking in the bracket

)

max pressing force (sensor to clip holes min dismantling force (sensor out of clips)

< 2.5 Nm (max. 3.0 Nm allowed)

< 170 N per screw

> 70 N per screw

The sensor bracket also enables horizontal and vertical adjustment of the ACC SCU radar beam to the vehicle longitudinal axis  see figure below. In our solution this is done with self-tapping adjustment screws in plastic mounts. The adjustment is done after attaching the sensor to the vehicle, using an external adjustment fixture, like an optical mirror. No external high frequency measurement equipment is needed.

Adjustment direction for screw driver directly from the front Adjustment range (proposal) Horizontal angle vertical angle

Permissible number of adjustments during vehicle life Adjustment accuracy relative to the vehicle longitudinal axis

± 3° ± 3°

0,2°

6 adjustment operations per adjustment screw over the adjustment range re-determined for each new type of vehicle

Speed of adjustment screw driver Max. 120 revolutions/min.

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The following sketches illustrate in principle the horizontal and vertical adjustment of the sensor. The procedure is as easy as the alignment of the head lamps and can be done at the same test bench in the customers plant.

adjustment screw for vertical adjustment

fixed screw

vert. reflector plate angle

sensor data

axis of azimuth adjustment

alignment controller

lens

axis of elevation adjustment

adjustment screw for horizontal

adjustment

alignment tool

horiz. reflector plate angle

reflector plate

horizontal scan

optional

reflector plate vertical scan optional

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vehicle axes evaluation

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Ambience Conditions and Mechanics

4 Electrical Data

4.1 Block diagram (Top level)

ACC2 (Adaptive Cruise Control) Top Level Block Diagram ACC2-SCU

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Gunn

Oscillator

Gunn

control

V Batt

GND

K-Ltg/WAU

CAN1-H

CAN1-L

CAN2-H

Signal

processing

and

Vstab

Power

supplies

Inter-

face

control

A/D

Lens-

heating

AE-DA/ELR 20204 0190

CAN2-L

RADOM /TGAP

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ACC Distance Control Radar 2nd Generation

GND

CAN2-L

CAN1-H

VBatt (Kl30)

K-Ltg/ WAU

CAN1-L

CAN2-H

RADOM / TGAP

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4.2 Pinning and Type of Connector

The following sketch shows the pinning of the ACC sensor. The number of pins are fixed to eight.

Pin-No. Designation Description Proposed wire size for

connecting harness 1 GND Sensor ground: connected to pin 31 0,75 mm 2 CAN1-H CAN1 High 0,5 mm 3 CAN1-L CAN1 Low 0,5 mm 4 K-Ltg 4 WAU

Diagnosis interface 0,5 mm

Wake up signal 0,5 mm 5 CAN2-H CAN2 High 0,5 mm 6 CAN2-L CAN2 Low 0,5 mm 7 Radome 7 TGAP

Output voltage for Radome heating 0,75 mm

Analogue signal input (time gap) 0,5 mm 8 V Batt Supply voltage for sensor 0,75 mm

: Either K-line or WAU possible

: Either Radome or TGAP possible

2 2 2 2 2 2 2

2 2

The 2nd CAN bus can be used as a private CAN for future ACC functions.

The plug itself is designed according the MQS System from AMP.

- The SCU plug is: AMP No.: C-114-19063-34 Kod A

- The harness wiring plug is: AMP No.: 153 42 29 (MQS System)

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Ambience Conditions and Mechanics

4.3 V Bat - Interface

The equivalent circuit diagram of the V Bat - interface is as follows:

Lens heating

Intelligent ASIC

VBat

C1 C2

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GND

SCU

Electrical specification: U

= 12 V (full operation from 10V to 16V)

nom

≤ 1.5 A (without lens heating)

max

≤

3.0 A (with lens heating at ambient temperature < 10°C)

max

V bat shall be fused externally by min. 10 A V bat shall be protected externally against over voltage and load dump up to 40 V

Quiescent Current: Sleep Mode: I (wake up not activated) I

Load capacitor: C1 + C2 < 300µF

≤ 50µA (without lens heating)

max

≤ 100µA (with lens heating)

max

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Ambience Conditions and Mechanics

4.4 CAN - Interfaces

The equivalent circuit diagram of the CAN - interface is as follows:

CANH

+5V

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Intelligent ASIC

D1 (opt.)

R3R1

CANL

D2 (opt.)

GND

SCU

Optional population: C1, C2 ≤ 100pF C3< 10nF R1,R2 < 1,5KΩ; R3, R4 = 61,9 bzw. 66,4 Ω

L: Choke 2 x 11µH (TDK, EPCOS) D: Dual Common Cathode Zener for ESD Protection

S:\ELR2\ACC2\Schnittstellenblätter für TKU\C AN.doc

The circuitry shows all possible options on the CAN.-interface.

If termination of the bus is not required the two 62 Ω-resistors(R or changed to higher value f.e. 1,3KΩ. The choke might be omitted if not required for

EMC-reason. The CAN bus is specified in „CAN Specification of the CAN physical layer for High-SpeedApplication up to 1Mbit/s“, dated October 1989.

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The following typical details are taken from this specification. These details are valid for an ECU which is separated from the bus and loaded with a 60Ω resistor:

Recessive state: (corresponding to logical 0)

Output voltage: Input range: Input resistor:

Dominant state: (corresponding to logical 1)

Output voltage: Input range:

-0,5 V ≤ U

-1,0 V ≤ U

1,5 V ≤ U 0,9 V ≤ U

Signal1/Signal2

> 9 kΩ

Signal1/Signal2 Signal1/Signal2

≤ 0,05 V

≤ 0,5 V

≤ 3,0 V ≤ 5,0 V

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4.5 Optional Diagnosis Interface (K-Line)

The equivalent circuit diagram of the diagnosis interface is as follows:

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K-Ltg

GND

SCU

VBatt

Intelligent ASIC

Electrical specification: R1 ≤ 110 kΩ R3 ≤ TBC Either R1 or R3 to be inserted R2 ≤ 80 Ω C1 ≤ 500 pF

Transmit Receive

logical „1“ logical „0“

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≥ 0.8 × V Bat ≥ 0.7 × V Bat

≤ 0.2 × V Bat ≤ 0.3 × V Bat

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Ω

Ambience Conditions and Mechanics

4.6 Optional Wake Up Line (WAU)

The equivalent circuit diagram of the wake-up interface is as follows:

VBatt

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Intelligent ASIC

Wake-up voltages:

WAU

GND

SCU

10K

Ω

C3C2

10K

R:\ELR2\ACC2\Schnittstellenblätter für TKU\WAU.doc

U U

WAU-On WAU-Off

≥ 4.0 V ≤ 2.0 V

C2 + C3 ≤ 200 nF

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Intelligent

Ambience Conditions and Mechanics

4.7

Optional Radome Heating Line (RADOM)

The equivalent circuit diagram of the RADOM - interface is as follows:

VBatt

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Electrical specification: U

= 12 V

nom

≤ 3 A at U

max

nom

RADOM

GND

SCU

ASIC

Quiescent current: Sleep mode: I

(wake up not activated) I

Active mode: I

max

(wake up activated)

Load capacitor: C

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≤ 22 nF

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≤ 10µA (T<25°C)

max

≤ 50µA (T<125°C)

≤ 200µA

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ACC Distance Control Radar 2nd Generation

VBatt

Ambience Conditions and Mechanics

4.8

Optional Lens Heating Line

The equivalent circuit diagram of the lens heating is as follows:

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Intelligent ASIC

GND

SCU

Electrical specification: U

= 12 V

nom

≤ 1.2 A at U

typ

≤ 1.5 A at U

max

Quiescent current: Sleep mode: Imax ≤ 10µA (T<25°C)

(wake up not activated) Imax ≤ 50µA (T<125°C)

Active mode: Imax ≤ 200µA

(wake up activated)

nom

Load capacitor: C

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≤ 22 nF

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Ambience Conditions and Mechanics

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Ambience Conditions and Mechanics

4.9

Optional Time Gap Input (TGAP)

The equivalent circuit diagram of the TGAP - interface is as follows:

3,35V

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ZTL

µController

A/D

GND

SCU

Logic levels to be discussed and defined between the customer and Bosch.

S:\ELR2\ACC2\Schnittstellenblätter für TKU\Timegap.doc

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5 Environmental tests

The tests described below will be carried out with the complete ACC-SCU including the 76,5 GHz transceiver-module, the connected wiring harness plug and the mounted

sensor bracket (according to the offer drawing). The “bracket only” tests will be carried out with an ACC-SCU- weight dummy, these tests are always passive tests. Qualification tests are intended to anticipate artificial ageing to simulate long term behaviour of the devices under test. Unless otherwise stated, the tolerances in the

temperatures are ± 2 °C and all laboratory tests are performed under the following

conditions:

• upper temperature (T

• lower temperature (T

) + 85 °C ± 2 °C

max

) - 40 °C ± 2 °C

min

• room temperature + 23 °C ± 5 °C.

• relative humidity 45 to 75 %

• test power 14 V ± 0,2 V

• operation mode active / non powered (valid for ACC-SCU)

Test criteria:

• Electrical function test completed without failures (if test values outside the tolerance,

a separate evaluation is necessary).

• No electrical or mechanical error function during the tests.

• No functionally related mechanical damages after the tests and no functionally related

foreign substances in the device under test after the kind-of-protection-tests.

After the tests the devices will be scraped not earlier than 1 year and not last than 2 years after SOP.

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The ACC2 sensor with its bracket will be approved according the following test sequence:

Initial electrical and visual test

11 DUT

High temp.

High temp. storage

Thermal cycle (artificial ageing)

5 DUT

endurance test

Low temp. storage

Thermal cycle (artificial ageing) / Thermal schock (pssive)

2 DUT

Random vibration test

Water protection IP X4K IP X6K IP X9K

8 DUT 1 DUT

Shock test

1 DUT

Dust protection IP 6x K

Damp heat, cyclic

Dip test

Salt mist

Comb. Salt/ humidity

Industrial climate

Condensation products

5 DUT

3 DUT

1 DUT

Stepped temp. Test

Temp. cycles (praxis)

Drop test

Resistance against painting

19 DUT

Final electrical and visual test

Chemical resistance

1 DUT

Stoning test

Customer specific tests in addition to this test sequence have to be discussed and fixed in detail together with Bosch and might be charged separately.

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6 EMC

6.1 Vehicle Tests

This EMC tests plan describes the general requirements to electronic equipment in the car. Additional tests or changed parameters may be necessary because of specific SCU requirements. The electronic design of the device, the location and wiring of the SCU in the car may cause the necessity of additional tests.

All tests are to be carried out within an certified EMC test laboratory at an air humidity between 45% ± 15% and a room temperature of 23°C ± 5°C unless otherwise stated.

In general vehicle tests are in customer’s responsibility. Test vehicles, which are identical to production vehicles, become available only at a very late date, so we must refer to the bench tests described below for internal release of the project. Nevertheless it is necessary to test the performance of the system in the vehicle.

If the SCU passes the bench tests, but fails the vehicle tests, then further investigations are necessary. To find an acceptable solution the responsible sensor development department will work together with the customer. The final release can only be made in a vehicle test.

The ACC2 sensor will be approved according the following EMC test sequence:

• Radiation Immunity according ISO 11541-2 (12.1995)

• Radiated Emission according CISPR 25 Section 2 (11.1995)

• Disturbance by other in-vehicle components

Further customer specific tests in addition to this test sequence have to be discussed and fixed in detail together with Bosch and might be charged separately.

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ACC Distance Control Radar 2nd Generation

Ambience Conditions and Mechanics

6.2 Bench Tests

The bench test plan for the ACC SCU is defined as follows:

• Conducted Immunity ESD according ISO TR 10605 (10.1994) and IEC 801-2 (04.1991) electrical transient conduction along supply lines according ISO 7637-1 (06.1990) electrical transient transmission by capacitive and inductive coupling according ISO 7637-3 (07.1995) immunity to abnormal supply voltage over-voltage sinusoidal ripple micro cut off (drop outs) supply voltage ramps short circuit to supply voltage

• Conducted Emission transient emission test according ISO 7637-1 (06.1990), CISPR 25 chapter 3 clause 11.2.1 (11.1995)

• Radiation Immunity strip line test according ISO 11452-5 (12.1995) BCI test method according ISO 11452-4 (12.1995) absorber lined chamber according ISO 11452-2 (12.1995) mobile phone simulation test according ISO 1145-2 (12.1995)

• Radiation Emission antenna measurement according CISPR 25 chapter 13

Strip line test according ISO 11452-5

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Further customer specific tests in addition to this test sequence have to be discussed and fixed in detail together with Bosch and might be charged separately.

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mechanics.doc