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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:

  1. Find the right folder - Navigate to the appropriate assembly folder (e.g., docs/assembly/steering/)
  2. Edit the bom.yaml file - Open the bom.yaml file in that folder
  3. Add your component - Copy an existing component entry and modify it with your new component's details
  4. Include key information:
  5. id: unique identifier (e.g., "motor_controller_v2")
  6. part_number: manufacturer part number
  7. description: what it is
  8. quantity: how many needed
  9. unit_cost: price per unit
  10. suppliers: where to buy it (name, url)

That's it! The component will automatically appear in BOM reports.

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, YOLOv5 models

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: Electronics Assembly

Key Components: - NVIDIA Jetson AGX Orin (€1500.00) - ESP32 WROOM-32 microcontroller (€3.50) - 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 YOLOv5 cone detection model

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

  1. Power System - Battery pack, BMS, charging setup
  2. Core Electronics - Orin computer, ESP32 microcontroller
  3. Sensors - ZED2 camera, angle sensors
  4. Propulsion - Motor, controller, transmission
  5. Steering - Motor, H-bridge, coupling
  6. Integration - Wiring, mounting, calibration

Working with YAML BOM Files

Adding New Components

  1. Locate the appropriate assembly folder
  2. Edit the bom.yaml file
  3. Follow the existing structure for consistency
  4. 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.