Bill of Materials (BOM)
Overview
This page provides a comprehensive list of all components required to build the driverless kart. Component data is now stored in YAML files within each assembly folder, following the project structure.
New BOM Management System
Components are now managed via separate YAML files in each assembly folder. The folder structure represents the BOM tree itself, eliminating synchronization issues.
How to Add Components to BOM
Adding a new component is simple:
- Find the right folder - Navigate to the appropriate assembly folder (e.g.,
docs/assembly/steering/) - Edit the bom.yaml file - Open the
bom.yamlfile in that folder - Add your component - Copy an existing component entry and modify it with your new component's details
- Include key information:
id: unique identifier (e.g., "motor_controller_v2")part_number: manufacturer part numberdescription: what it isquantity: how many neededunit_cost: price per unitsuppliers: where to buy it (name, url)
That's it! The component will automatically appear in BOM reports.
💰 Cost Summary
| Assembly | Components | Total Cost |
|---|---|---|
| Electronics | 7 | €1536.50 |
| Hydraulics | 8 | €510.90 |
| Power | 4 | €529.00 |
| Powertrain | 2 | €152.46 |
| Powertrain_Fasteners | 5 | €4.70 |
| Powertrain_Transmission | 3 | €40.00 |
| Sensors | 2 | €450.00 |
| Steering | 4 | €152.00 |
| Steering_Fasteners | 4 | €3.05 |
| TOTAL | 39 | €3378.61 |
| ## BOM Structure |
The BOM is organized by assembly with YAML files containing detailed component specifications:
docs/assembly/
├── powertrain/
│ ├── bom.yaml # Motor, throttle pedal
│ ├── transmission/bom.yaml # Chain, sprockets
│ └── fasteners/bom.yaml # All powertrain fasteners
├── steering/
│ ├── bom.yaml # H-bridge, motor, sensor, coupling
│ └── fasteners/bom.yaml # All steering fasteners
├── electronics/
│ ├── bom.yaml # Orin, ESP32, DAC, level shifter
│ └── power/bom.yaml # Battery cells, BMS, auxiliary battery
├── sensors/bom.yaml # ZED2 camera, YOLOv11 models
└── hydraulics/bom.yaml # Hydraulic brake components and service spares
🔍 Searchable Parts Database
| ID ↕ | Part # ↕ | Description ↕ | Assembly ↕ | Category ↕ | Qty ↕ | Cost ↕ | Status ↕ | Critical ↕ |
|---|---|---|---|---|---|---|---|---|
| nvidia_jetson_agx_orin | JETSON-AGX-ORIN-DEVKIT | NVIDIA Jetson AGX Orin Development Kit | electronics | Computer | 1 | EUR 1500.00 | Active | Essential |
| esp32_s3 | ESP32-S3-WROOM-1-N16R8 | ESP32-S3 microcontroller module (16 MB flash, 8 MB octal PSRAM) — MCU of the Kart Medulla interface PCB | electronics | Microcontroller | 1 | EUR 5.00 | Active | Essential |
| esp32_wroom_32 | ESP32-WROOM-32 | ESP32 microcontroller module — retired; was hand-wired in the kart (no PCB) before the ESP32-S3 Medulla PCB | electronics | Microcontroller | 1 | EUR 3.50 | Legacy | Essential |
| orin_adapter_board | CUSTOM-ORIN-ADAPTER-V1.0 | Custom Orin adapter board v1.0 | electronics | Pcb | 1 | EUR 25.00 | Active | Essential |
| kart-medulla_shutdown_mosfet | TBD-MOSFET | Shutdown MOSFET (low-side or high-side) | electronics | Mosfet | 1 | EUR 0.00 | Pending | Essential |
| kart-medulla_dac_mcp4922 | MCP4922-E/SL | Dual 12-bit SPI DAC — generates CMD_ACC and CMD_BRAKE on the Kart Medulla PCB | electronics | Dac | 1 | EUR 3.00 | Active | Essential |
| kart-medulla_dual_op_amp | TBD-DUAL-OPAMP | Dual op-amp for ESP32 DAC scaling | electronics | Op Amp | 1 | EUR 0.00 | Pending | Essential |
| tony_extreme_brake_pump | Tony Kart BS1 family; exact fitted part number unrecorded | Twin-piston hydraulic brake master cylinder, legacy Tony Kart Extreme arrangement, without recovery reservoir | hydraulics | Brake | 1 | EUR 0.00 | Installed | Essential |
| tony_extreme_rear_caliper | Tony Kart BS1 family; exact fitted part number unrecorded | Legacy rear hydraulic brake caliper, two-piece construction | hydraulics | Brake | 1 | EUR 0.00 | Installed | Essential |
| tony_extreme_rear_disc | Tony Kart BS1/BS2 rear disc reference TK0051.00 | Rear hydraulic brake disc | hydraulics | Brake | 1 | EUR 0.00 | Installed | Essential |
| tony_extreme_brake_hoses | M10x1.0 female inverted flare; exact hose part number unrecorded | Flexible hydraulic brake hoses | hydraulics | Brake | 1 | EUR 0.00 | Installed | Essential |
| tony_bs1_pump_spare | TK0029.BB | Complete Tony Kart BS1/BS2 twin-pump assembly, compatible spare candidate | hydraulics | Brake | 1 | EUR 176.95 | Compatible Spare | Essential |
| tony_bs1_caliper_spare_pre2000 | TK0082.BA | Tony Kart BS1 rear caliper, pre-2000 catalogue reference | hydraulics | Brake | 1 | EUR 193.95 | Compatible Spare | Essential |
| tony_bs1_hose_kit | TK0081.B1 | Tony Kart BS1/BS3 steel-braided brake hose kit | hydraulics | Brake | 1 | EUR 140.00 | Compatible Spare | Essential |
| tony_bs1_pad_set | BRTK015N | Newfren replacement rear brake pads listed for Tony Kart Extreme hydraulic brakes | hydraulics | Brake | 1 | EUR 0.00 | Compatible Spare | Essential |
| molicel_p42a_cells | P42A | Molicel P42A 21700 lithium-ion cells | power | Battery Cells | 52 | EUR 4.50 | Active | Essential |
| jiabaida_bms_100a | JBD-SP22S003B | Jiabaida Smart BMS 100A with Bluetooth and UART | power | Bms | 1 | EUR 85.00 | Active | Essential |
| car_battery_12v | 12V-CAR-BATTERY | 12V automotive battery for sensors | power | Auxiliary Battery | 1 | EUR 60.00 | Active | Essential |
| battery_pack_assembly | CUSTOM-PACK-13S4P | Custom 13S4P battery pack assembly | power | Mechanical | 1 | EUR 150.00 | Active | Essential |
| kunray_my1020_motor | MY1020 | Brushless DC motor with controller | powertrain | Motor | 1 | EUR 150.00 | Active | Essential |
| throttle_pedal_ss49e | THROTTLE-PEDAL-HALL | Throttle pedal with SS49E Hall sensor | powertrain | Sensor | 1 | EUR 2.46 | Active | Essential |
| motor_mount_bolts | M8x30-HEX | Motor mount bolts | powertrain_fasteners | Fasteners | 4 | EUR 0.50 | Active | Essential |
| motor_mount_nuts | M8-NUT | Motor mount nuts | powertrain_fasteners | Fasteners | 4 | EUR 0.15 | Active | Essential |
| front_sprocket_bolts | M6x16-HEX | Front sprocket bolts | powertrain_fasteners | Fasteners | 3 | EUR 0.30 | Active | Essential |
| chain_tensioner_hardware | M6x20-HEX | Chain tensioner hardware | powertrain_fasteners | Fasteners | 2 | EUR 0.35 | Active | Essential |
| throttle_pedal_mount_bolts | M5x12-HEX | Throttle pedal mount bolts | powertrain_fasteners | Fasteners | 2 | EUR 0.25 | Active | Essential |
| iris_219_chain | IRIS-219-100 | IRIS 219 pitch gold chain | powertrain_transmission | Transmission | 1 | EUR 15.00 | Active | Essential |
| corona_219_aluminum | CORONA-219-ALU | 219 pitch aluminum rear sprocket | powertrain_transmission | Transmission | 1 | EUR 20.00 | Needs Replacement | Essential |
| custom_219_pinion | CUSTOM-219-PINION | Custom 219 pitch front sprocket | powertrain_transmission | Transmission | 1 | EUR 5.00 | Active | Essential |
| stereolabs_zed2 | ZED2 | Stereolabs ZED2 stereo vision camera | sensors | Camera | 1 | EUR 450.00 | Active | Essential |
| yolov11_detection_model | CUSTOM-YOLOV11-CONES | Custom YOLOv11 model for cone detection | sensors | Software | 1 | EUR 0.00 | Active | Essential |
| cytron_md25hv | MD25HV | 25A high voltage H-bridge motor driver (7V-58V) | steering | Electronics | 1 | EUR 55.00 | Active | Essential |
| steering_motor_24v | STEERING-24V-MOTOR | 24V DC steering motor (operated at 12V) | steering | Motor | 1 | EUR 80.00 | Active | Essential |
| as5600_angle_sensor | AS5600 | Hall effect rotary position sensor | steering | Sensor | 1 | EUR 2.00 | Active | Essential |
| steering_coupling | STEERING-COUPLING-10MM | Motor to steering shaft coupling | steering | Mechanical | 1 | EUR 15.00 | Active | Essential |
| coupling_motor_bolts | M6x20-HEX | Coupling to motor bolts | steering_fasteners | Fasteners | 4 | EUR 0.35 | Active | Essential |
| sensor_mount_screws | M3x8-HEX | Sensor mounting screws | steering_fasteners | Fasteners | 2 | EUR 0.20 | Active | Essential |
| motor_bracket_bolts | M6x30-HEX | Motor bracket bolts | steering_fasteners | Fasteners | 2 | EUR 0.40 | Active | Essential |
| main_coupling_bolt | M8x25-HEX | Main coupling bolt | steering_fasteners | Fasteners | 1 | EUR 0.45 | Active | Critical |
Assembly Overview
🔧 Powertrain Assembly
Components: Motor, transmission system, throttle control - Main Components: Powertrain BOM - Transmission: Transmission BOM - Fasteners: Powertrain Fasteners BOM - Documentation: Powertrain Assembly
Key Components: - Kunray MY1020 3000W motor (€150.00) - IRIS 219 chain and sprocket system (€40.00) - Hall effect throttle pedal (€2.46)
🎮 Steering Assembly
Components: Motor, sensor, H-bridge, coupling - Main Components: Steering BOM - Fasteners: Steering Fasteners BOM - Documentation: Steering Assembly
Key Components: - Cytron MD30C H-bridge (€45.00) - AS5600 magnetic angle sensor (€2.00) - 24V DC steering motor (€80.00)
💻 Electronics Assembly
Components: Computing, control, communication - Main Components: Electronics BOM - Documentation: Kart Medulla (ESP32-S3)
Key Components: - NVIDIA Jetson AGX Orin (€1500.00) - ESP32-S3-WROOM-1-N16R8 microcontroller (16 MB flash, 8 MB octal PSRAM; MCU of the Kart Medulla PCB; ~€5) - ESP32-WROOM-32 microcontroller (€3.50, retired — was hand-wired in the kart before the Medulla PCB) - Custom Orin adapter board (€25.00)
⚡ Power Assembly
Components: Main battery pack, BMS, auxiliary power - Main Components: Power BOM - Documentation: Power Assembly
Key Components: - 52x Molicel P42A cells in 13S4P (€234.00) - Jiabaida Smart BMS 100A (€85.00) - 12V auxiliary battery (€60.00)
📷 Sensors Assembly
Components: Vision system, AI models - Main Components: Sensors BOM - Documentation: Sensors Assembly
Key Components: - Stereolabs ZED2 stereo camera (€450.00) - Custom YOLOv11 cone detection model
🛑 Hydraulic Braking Assembly
Components: Installed brake circuit and compatible service spares - Main Components: Hydraulics BOM - Documentation: Hydraulics Assembly
Key Components: - Legacy Tony Kart BS1-family brake pump, caliper, rear disc and hoses (installed; exact fitted part numbers need physical confirmation) - Catalogue-era BS1/BS2 pump spare (€176.95) - Catalogue-era pre-2000 BS1 rear-caliper spare (€193.95) - BS1/BS3 steel-braided hose kit (€140.00) - Newfren replacement pad set (supplier listing: AUD $71.50; confirm fit before ordering)
Estimated Project Costs
| Assembly | Estimated Cost | Key Items |
|---|---|---|
| Powertrain | €195 | Motor (€150), transmission (€40), fasteners (€5) |
| Steering | €135 | H-bridge (€45), motor (€80), sensor (€2), fasteners (€8) |
| Electronics | €1530 | Orin computer (€1500), ESP32 (€4), adapter (€25) |
| Power | €380 | Li-ion cells (€234), BMS (€85), 12V battery (€60) |
| Sensors | €450 | ZED2 camera (€450) |
| Total | €2690 | Excludes chassis, wiring, mechanical hardware |
Cost Estimates
Prices are approximate and subject to change. Always verify current pricing from suppliers.
Component Status
✅ Active Components
Currently used and functional in the kart.
⚠️ Needs Replacement
Known to be damaged or worn: - 219 aluminum rear sprocket (damaged from incompatible chain use)
🔧 Custom Components
Require fabrication: - Custom 219 front sprocket (laser cut for 10mm shaft) - Orin adapter board (EasyEDA design available) - Battery pack assembly (professional assembly recommended)
Supplier Information
Primary Suppliers
- Electronics: Mouser, Digi-Key, Adafruit
- Karting Parts: KPS Racing
- Batteries: Authorized Molicel distributors
- Vision Systems: Stereolabs
- General Components: AliExpress, Amazon (for non-critical parts)
Quality Guidelines
- ✅ Use official distributors for critical electronic components
- ✅ Verify specifications before ordering
- ⚠️ AliExpress/Amazon acceptable for mechanical parts and sensors
- ❌ Avoid counterfeit components for safety-critical systems
Assembly Priority
- Power System - Battery pack, BMS, charging setup
- Core Electronics - Orin computer, ESP32 microcontroller
- Sensors - ZED2 camera, angle sensors
- Propulsion - Motor, controller, transmission
- Steering - Motor, H-bridge, coupling
- Integration - Wiring, mounting, calibration
Working with YAML BOM Files
Adding New Components
- Locate the appropriate assembly folder
- Edit the
bom.yamlfile - Follow the existing structure for consistency
- Include all required fields: id, part_number, description, quantity, cost, suppliers
YAML File Structure
assembly: "assembly_name"
description: "Assembly description"
components:
- id: "unique_component_id"
part_number: "MANUFACTURER-PART-NUMBER"
description: "Component description"
quantity: 1
unit_cost: 0.00
currency: "EUR"
status: "active"
criticality: "essential"
suppliers:
- name: "Supplier Name"
url: "https://supplier.com/product"
verified: true
specifications:
key: "value"
notes: "Additional information"
Future Automation
A BOM aggregation script is planned to automatically generate: - Complete cost summaries - Supplier contact lists - Component status reports - Assembly checklists
This BOM system reflects the complete restructure from hardware-based to assembly-based organization, with component data stored in YAML files following the project's folder structure.