Tamper detection for e-bikes with BOSCH Engines
Engine and tuning chip manufacturers are in constant competition. Some try to prevent tuning with technical refinements and software updates, while others upgrade their chips and modules accordingly. So far, however, tuning specialists such as VOLSPEED, SPEEDBOX or PEARTUNE have always managed to react to the manufacturers' changes. Using the example of the BOSCH Smart System (BES3) and VOLSPEED tuning chips, we show the current state of affairs (June 2023):
The famous error 504
You should know that BOSCH introduced tamper detection in 2019 with the release of the Performance Line CX Gen 4, which was also integrated into the older Gen 2 and Gen 3 Engines through software updates in the following months. This software function in the drive motor is designed to prevent motor assistance above 25 km/h being detected on pedelecs by using various sensor signals to estimate the riding speed and compare it with the speed determined via the sensor on the rear wheel, which has been manipulated via the Tuning Chip. If major deviations are detected, error 504 occurs, which is notorious among pedelec riders. This manipulation detection is also present in the Smart System, but with the modified error code 0x524001.
In its experience with tamper detection, VOLSPEED has noticed a clear difference between different software versions and motor generations (Gen 2, Gen 3, Gen 4). However, the frequency of a 504 error also depends heavily on the actual speed up to which engine support is available, i.e. how high the limit is raised with the Tuning Chip. In the past, there were hardly any problems with the manipulation detection up to a limit of 35 km/h, except for a single software version of the Performance Line CX Gen 4, which caused problems even without a Tuning Chip.
The new tuning chip from VOLSPEED
Based on the experience with tamper detection, VOLSPEED launched the VOLspeed V4 for BOSCH in October 2021, in which the adjustable limit is generally limited to 45 km/h and further improvements mean that a 504 error no longer occurs even in the 35-45 km/h range. They have also integrated these findings into the new Tuning Chip for the Smart System, which is also limited to 45 km/h and offers the highest possible immunity to tamper detection. However, VOLSPEED cannot guarantee that the error 0x524001 will not occur, as there are too many factors that influence the occurrence of the error.
VOLSPEED advises not to set the limit higher than absolutely necessary to prevent the tampering detection from responding. For example, if you do not drive faster than 35 km/h anyway, you should not set the limit any higher. We also advise against software updates to the drive system, as the manipulation detection could be adapted to recognise the tuning or the functionality could be generally prevented due to changes to the data communication. Please also note that it is generally not possible to perform a software downgrade if malfunctions occur with the new software.
More about tuning for BOSCH drives.
