Bosch DCU17HD01-4.41 Engine Control Module Teardown

Overall Significance

When we tear down automotive modules - their exact function(s) as well as what vehicle(s) they come from are often difficult to ascertain, and for this module, it is still the case - we don't know much about the device as a functioning unit, other than it is built by (or for) Bosch. The device is labeled as Made in Germany - but that does not preclude Bosch from outsourcing to EMS providers for manufacturing. The design leverages components from the mid 2000's and seems to be contemporary. Unfortunately the exact part reference from this module was hard to glean - and not much information could be found on this module.

Bosch DCU17HD01-4.41 Engine Control Module Main Image

The parts in this design have design dates ranging from 2003 to 2007 approximately - though a label on the device itself suggests a 2009 production timeframe. The components in this analysis do not, at first glance appear to be obsolete, but given the overall age of the IC's it is worth verifying obsolescence of the this bill of materials as parts are likely to be approaching maturity. This design uses Infineon for the MCU chipset - an 80MHz processor. The Infineon solution here is comprised of the MCU and a companion IC (SAK-TC1766-192F80HL, and SAK-CIC751-EOM16T). Several Bosch designed parts are leverage (4 in all - a power switch IC, a MOSFET driver IC, and two power supply ICs). This makes the whole solution somewhat 'proprietary' - but this does not guarantee a more competitive market, as vigorous competition in the silicon market and a host of competing power solutions exist from independent vendors.

Target Market

Captive Automotive

Modules such as this are designed specifically to control a specific engine(s) - and as a result is really just captive market product designed to accompany OEM equipment and to be offered as spares for maintenance of engines.

Bosch DCU17HD01-4.41 Engine Control Module - Main PCB Top

Unknown per press release

Based on the circa of dates found on this device - it appears to be from anywhere from the 2006 - 2009 period. Information found is inconclusive.

Pricing and Availability

Unknown

Pricing not collected for this system - not a 'retail' product per se - would be sold through equipment and engine service centers. Prices for the ECUs found on Bosch's own website range from $300 to $3000 Euros at retail. This unit appears that it could be the kind selling for 300 Euros - but this model was not an exact match for those found.

Bosch DCU17HD01-4.41 Engine Control Module - Main PCB Bottom

Worldwide availability assumed.

Volume Estimations

300,000 Annual Production Units
4 Total Years

For the purposes of this teardown analysis, we have assumed an Annual Production Volume of 300000 units and a Product Lifetime Volume of 4 year(s).

Teardown volume and production assumptions are primarily used for our cost analysis in terms of amortized NRE and tooling costs, especially for custom components specific to the model being analyzed (mechanical components especially). Unless assumed volumes are different by an order of magnitude, minor changes in volume (say 1 million vs. 2) rarely have a large net effect on our final analysis because of this.

Bosch DCU17HD01-4.41 Engine Control Module Cost Analysis

Our cost analysis is meant to be as calibrated as possible to the production volumes being used, but also particular to the level of pricing that we would expect a company like Bosch to be able to achieve in the market. 'Automotive' grade component pricing is applied when the found specs match such requirements.

Total BOM: $59.72
Top Cost Drivers below: $47.87
% of Total BOM 80%

Main Cost Drivers below

Infineon SAK-TC1766-192F80HL MCU - 32-Bit, 80MHz, Automotive- (Qty: 1)
Bosch Pin Header - Right Angle, Quad Row, Dual Shell, Automotive Shrouded, 4 Snap-In Pins- (Qty: 1)
Enclosure, Main, Bottom - Die-Cast Aluminum Alloy- (Qty: 1)
Bosch CJ945C Power Switch IC - 18 Low-Side Drivers, Open-Circuit & Overtemperature Detection- (Qty: 1)
4-Layer - FR4, Lead Free- (Qty: 1)
Enclosure, Main, Top - Stamped/Formed Metal- (Qty: 1)
Bosch CY146 MOSFET Driver - 6x High Side / Low Side Switch, Configurable- (Qty: 1)
Bosch CY320 Power Supply IC - 8 Regulators, 3-Level Watchdog- (Qty: 1)
Bosch CY141 Power Supply IC - Adjustable Step Up/Down Regulators, 5 Output Stages- (Qty: 1)
Renesas NP110N04PUG MOSFET - N-Channel, 40V, 110A- (Qty: 2)

Not Included in Analysis

The total materials and manufacturing costs reported in this analysis reflect ONLY the direct materials cost (from component vendors and assorted EMS providers), AND manufacturing with basic test. Not included in this analysis are costs above and beyond the material manufacture of the core device itself - cost of intellectual property, royalties and licensing fees (those not already included into the per component price), software, software loading and test, shipping, logistics marketing and other channel costs including not only EMS provider and the OEM's margin, but that of other resellers. Our cost analysis is meant to focus on those costs incurred in the manufacture of the core device and exceptionally in some circumstances the packaging and literature as well.

We do provide an Excel tab 'Overall Costs' where a user can enter their known pre and post production costs to build a per unit cost reflective of theirs actual expenditures.

Country of Origin

For the purposes of this analysis, we are assuming the following country(ies) of origin for each level of assembly, based on a combination of 'Made In' markings, and/or assumptions based on our knowledge of such equipment.

Main PCB - Germany
Other - Enclosures / Final Assembly - Germany

Country of origin assumptions relate directly to the associated cost of manufacturing, where calculated by iSuppli. In the cases of 'finished' sub-assemblies sold as a unit, we do not calculate internal manufacturing costs, but rather assess the market price of the finished product in which case country of origin assumptions may or may not have a direct effect on pricing.

Labor rates are applied directly only to hand inserted components and systems in our bill of materials, and although regional assumptions do, these new rates do not have a direct effect on our modeled calculations of placement costs for automated SMD assembly lines. "Auto inserted components (such as SMT components) placement costs are calculated by an iSuppli algorithm which allocates a cost per component based on the size and pincount of the device. This calculation is affected by country or region of origin as well.

Design Complexity

Component counts by assembly and the number of assembly are indicators of design complexity and efficiency.

Component Qty: 412 - Main PCB
Component Qty: 12 - Other - Enclosures / Final Assembly
Component Qty: 424 - Grand Total

Component counts are usual a direct function of the functionality of the design - the more features a device offers, generally the more components we find. It's rare we see a drastically lower component count for the same function. We recently saw a Magnetii Marelli module that seems similar and nearly half again the component count (~250 components). It is typically possible to integrate component counts by using more current IC vendor offerings, as the market tends to offer more and more integrated solutions with each passing year.

Design Notes

This design uses Infineon for the MCU chipset - an 80MHz processor - a near equivalent to the Freescale part used in the Cummins CM2150. The Infineon solution here is comprised of the MCU and a companion IC (SAK-TC1766-192F80HL, and SAK-CIC751-EOM16T).

Several Bosch designed parts are leverage (4 in all - a power switch IC, a MOSFET driver IC, and two power supply ICs). This makes the whole solution somewhat 'proprietary' - but this does not guarantee a more competitive market, as vigorous competition in the silicon market and a host of competing power solutions exist from independent vendors.

Bosch DCU17HD01-4.41 Engine Control Module - Disassembly View 1