Cost-Innovative 2-Wheeler ECU with Novel Molded Housing Concept and Direct Connecting System

In order to face the requirements of 2-wheeler engines (e.g. with respect to legislation) in the fast growing markets world-wide, Robert Bosch GmbH is developing an innovative Electronic Control Unit (ECU) with molded housing and direct connecting system (DCS). In this paper the advantages of this concept are shown in comparison to standard ECUs (i.e. potted and metal based housings).

The ECU production process is described as well as the physical characteristics of the ECU mold body with regard to thermal behavior and temperature cycling robustness. The second innovation besides the novel housing is the direct connection system that forms a common unit with the molded ECU, thus allows a high vibration resistance. The direct connector integrates functional elements like connecting, sealing and holding.