Bosch Rexroth AG Mobile Elektronics Mobile 2003 19

Electronics for Mobile Hydraulics -

The Seven Building Blocks for
Maximum Customer Benefits
Solutions for customers, from the small-scale user to the
large-scale manufacturer

Introduction
A few years ago, Rexroth set itself a
new emphasis in mobile hydraulics:
Mobile electronics would be its future
springboard to innovative applicati-
ons. Electronics are often indispens-
able as customer requirements con-
cerning the scope and quality of ma-
chine functions and the fulfillment of
safety and environmental standards
become ever more far-reaching. The
seven building blocks of the Rexroth
mobile electronics strategy form a so-
lid foundation for maximizing custo-
mer benefits:

Figure 1: The seven building blocks of our mobile electronics strategy

Building block 1: For Rexroth customers, this product

Corporate synergy for
the world market leader
in mobile hydraulics
Rexroth supplies a unique variety of
components and systems for drive
and control of hydraulic work ma-
chinery. In addition to the hydraulics
and gearing, we can also offer a coor-
dinated range of electronic compon-
ents. This is not just to limited indivi-
dual components; we offer a full range
of control panel, control units, sensors
and software.
Author:
Albrecht Benz BRM-ME/PL
strategy has a number of significant
advantages: for almost every mobile
machines (fig. 2), we can supply the
optimum solution from an enormous
modular system of standard hydraulic
and electronic components. And this
is not restricted to construction ma-
chinery, commercial vehicles, agricul-
tural and forestry implements or ma-
terial handling equipment. In every
field, we stand as proof positive of
what has made Bosch Rexroth the
world market leader: reliability, cost-
effectiveness, robustness and ease of
use combined with progressive tech-
nology.
20 Mobile 2003 Mobile Elektronics Bosch Rexroth AG

structure with professional develop-

ment and production methods.
The programming may be carried out
either by Rexroth or by the end custo-
mer, depending on whether the em-
phasis is on leveraging our in-house
knowledge of applications or on pro-
tecting the customer’s specialist
knowledge of the application - or
perhaps even simply taking account of
the current workload and available
personnel capacity.
The BODAS programming system can
be used in both cases. This is a user-
friendly programming environment
for Rexroth control units.
Standard software such as templates,
Figure 2: Examples of Rexroth’s wide-ranging expertise with applications that use
modules and a function library are
effectively interacting hydraulic and electronic components
further aids to rapid implementation.
Individual adaptations are also possi-
Building block 2: stem guarantees the highest quality ble with BODAS. And if this is not
standards and low prices for small- enough, then the Rexroth specialists
From individual machi- scale users to large-scale production. can always make use of highly ef-
nes to large-scale pro- If special functions require an indivi- ficient C-programming for special ap-
dually tailored solution or are needed plications.
duction - The Rexroth to reduce the cost of large numbers
strategy for mobile elec- per year, then we can do this as well -
tronics follows custo- whilst still combining the modular

mer requirements
The product strategy for mobile elec-
tronics mirrors the structure of our
customers: from the small-scale ma-
nufacturer producing just one highly
specialized municipal vehicle per
month, for example, to the major cu-
stomer who builds many thousands of
fork-lift trucks every year.
Both of these receive from us a range
of products and services tailored to
their needs.
The hardware is based on a modular
system of control units, sensors and
machine controls. This modular sy- Figure 3: Strategic positioning of mobile electronics
Bosch Rexroth AG
We offer four fundamentally different
ways to implement an application
project. These are illustrated below:
A) The standard solution for
hardware and software, with
practically no development costs
(example of the GLR load limiting
control).
No additional development of hard-
ware or software is needed for use in
different applications, e.g. a wide ran-
ge of construction machinery. The ad-
aptations are made solely by setting
parameters in the BB-3 control panel
or the user-friendly BODEM PC soft-
ware.
Our example: in many different appli-
cations for mobile machiness, the use
of an electronic load limiting control
for power management between indi-
vidual hydraulic circuits allows smal-
ler diesel engines to be installed. This
cuts costs, both on the initial equip-
ment and on fuel consumption du-
ring operation.
For open, hydrostatic circuits, Rexroth
can supply a standard solution consi-
sting of:
– RC control unit with CAN bus link
for communicating with the diesel
engine,
– GLRA software module
– Interface to BB-3 or the BODEM
PC parameter assignment and dia-
gnostics software package
(For detailed information on the GLR
load limiting control, see RE 95055)
Mobile Elektronics
Figure 4: Mobile crane
There are also similar standard soluti-
ons with hardware and off-the-shelf
software, e.g. for a universal pump
control (PST), the combined pump/
motor control (PMS) and the con-
stant speed drive (CSD), for example.
B) The hardware modular system
with application-specific software
solution - using the paver as an
example
A control unit with the appropriate
number of inputs/outputs and inter-
faces can be selected for many diffe-
rent tasks from the RC control unit
modular system. Hardware that has
been tried and tested in large quanti-
ties is used, thus avoiding hardware
development costs. The product range
also includes standard sensors for the
common measured variables, such as
speed, pressure and angle.
Mobile 2003 21
Figure 5: Paver
Our example: the paver contains a
number of hydrostatic drives that per-
form the following functions:
– Open or closed-loop control of the
driving speed
– Steer-by-wire for track finishers:
closed-loop controlled straight-
ahead driving and turning
– Changing the direction of travel by
reversing
– Pump control for rammers and
other functions
Rexroth has developed software mo-
dules for the above functions on the
basis of many years’ experience with
equipping pavers. These modules are
created using professional develop-
ment methods and strict internal pro-
gramming guidelines in order to
ensure high functional reliability and
their effective reuse in new projects.
On this basis, new application softwa-
re can be created for a customer pro-
ject with short development times
and then, if necessary, additional pro-
gramming may be carried out to add
new functions.
22 Mobile 2003 Mobile Elektronics
C) Optimized hardware and soft-
ware for special applications -
using the example of the EHR
hitch control
Rexroth develops perfectly tailored
standard hardware and software for
the typical areas of application of mo-
bile machines.
Our example: The hitch control as a
sophisticated control subfunction in
modern tractors has been optimized
over the years at Bosch and is used in
large numbers today.
Application-specific use in the tractor
allows the hardware specification to
be accurately refined, thus optimizing
the development costs for large-scale
production. In the software, as well,
functions such as position control,
draft control and active ride control
are fixed parts of the EHR, which me-
ans that application-specific adaptati-
ons are limited primarily to the inter-
faces. Rexroth has also optimized the
software with respect to memory re-
quirement and run-time, and de-
veloped it for very specific hardware.
Rexroth is always able to build on this
technology in order to create optimi-
zed, application-specific solutions for
new systems in mobile machiness, e.g.
CVT transmission controls.
D) Customer-specific component
development - using the example
of a joystick for the fork-lift truck
For mobile machines, large-scale pro-
duction requires all the components
to be optimized, i.e. the control units,
sensors and control panels. Characte-
ristics such as 12 V or 24 V power
supply, number of inputs and outputs,
open or closed-loop current control
are considered individually at the im-
plementation stage.
Figure 6: Tractor
Our example: The joystick for fork-lift
trucks as a customer-specific compo-
nent. With its very special handle and
functional elements integrated in it, it
meets all the ergonomic requirements
of a special machine.
Of course, the less application-specific
parts of this joystick, such as the hou-
sing and the PCB’s are standardized,
and make use of the experience and
proven capabilities of many compara-
ble applications. Nevertheless, there is
still plenty of room for customers’
wishes. For example, if a proprietary
CAN communication protocol is re-
quired in the software, then this can
be seamlessly incorporated.
Bosch Rexroth AG
Figure 7: Joystick
Building block 3:
The Bosch Factor
Extremely high demands are placed
on the electronics in mobile machi-
nes. Vibration, shock, cold, heat, wa-
ter, chemical fluids and electromagne-
tic radiation from mobile telephones,
for example, are potential sources of
interference to which a system must
be resistant. The quality of each indi-
vidual component is of immense sig-
nificance. This is why we produce im-
portant components ourselves, and
set great store by our thorough quality
testing.
And this is where a particular advan-
tage that is only available from Rex-
roth in the field of mobile hydraulics
comes into play: as a company within
the Bosch Group, we have access to
the very best automotive electronics
skills. The use of electronics in pas-
senger cars and commercial vehicles is
one of Bosch’s traditional strengths -
both leading the way and acting as a
yardstick for the quality of the elec-
tronics in mobile machines. We also
have unrestricted access to the latest,
application-oriented research and ad-
vanced development - the Bosch R&D
Bosch Rexroth AG
thinktank is located in the building
next-door to our development head-
quarters in Schwieberdingen, Stutt-
gart.
Critical electronic components are
subjected to particularly stringent in-
ternal load and soldering tests at
Bosch. And our control units are pro-
duced on exactly the same production
lines as the Bosch electronics for pas-
senger vehicles. The „Bosch advan-
tage“ comes into play early in the de-
velopment cycle. Every component is
exposed to the harshest tests on vibra-
tion devices, in cold and heat cham-
bers, in interference field laboratories
and salt mist chambers. All these tests
conform to international standards
and are selected specifically for the
needs of mobile hydraulics. This is
why you can rely on our components,
even under the most extreme conditi-
ons. Quality made by Bosch - imple-
mented for your particular require-
ments.
Building block 4:
The CAN bus - Backbo-
ne of a universal hard-
ware concept
Today, the CAN bus can be found in
every car and in many commercial ve-
hicles. It is just as essential for com-
munication between the electronic
components in the vehicle as the tele-
phone line is for every person. The
CAN bus was defined by Bosch back
in 1985, and now it is used and re-
cognized around the world through
the ISO 11898 standard. This system
is used to minimize the complex wi-
ring looms in vehicles and machines.
Mobile Elektronics
Intelligent components from Rexroth
such as control units, joysticks, dis-
plays and sensors communicate with
one another via the CAN bus. Com-
munication is based on the SAE J1939
protocol. This protocol is already wi-
dely used in vehicles by the diesel
engine’s injection system. The proto-
col allows components from different
manufacturers to communicate with
one another, since they speak a „com-
mon language“. For example, Rexroth
control units can exchange data di-
rectly with the control unit of the die-
sel engine, thus allowing optimum
control of the overall system, consi-
sting of the diesel engine, hydrostatic
travel drive and working hydraulics.
All components connected to the
CAN bus can be accessed centrally for
diagnostic purposes. This makes the
machine much easier to maintain.
Our example: Distributed electronics
and CAN communication in the ex-
ample of a container stacker. In com-
plex open and closed-loop control sy-
stems for mobile machines, it is a
CAN-Bus
Figure 8: The CAN bus, the backbone of our hardware strategy
Mobile 2003 23
good idea to map individual functio-
nal units as subsystems. In this way,
variant devices can be broken down
into modules, and functions can be
divided up into easy-to-understand
subsystems with clear interfaces.
On a container stacker (fig. 9), for ex-
ample, the travel drive and the winch
control are two such subsystems that
are each controlled by a separate con-
trol unit. The control unit for the tra-
vel drive contains functions such as
the speed control, drive slip control,
constant speed drive and diesel over-
speed protection. The winch control
unit controls the hydraulic pump and
motor, the valves for raising and lo-
wering, and the brake. The controls
use the CAN to exchange data such as
speed, torque, pedal position and
temperatures between one another
and with the diesel engine.
24 Mobile 2003 Mobile Elektronics Bosch Rexroth AG

Standard Specialized Customer-specific

Control unit Universal, Special, Customer-specific
series RC z.B. series EHR
Analog inputs 4 - 24, 12 - 14
(min. 0, max. 40)
Frequency inputs 2 - 10, 0-4
(min. 0)
Switch inputs 4 - 14, 0-6
(min. 0, max. 48)
Proportinal outputs 2 - 12 2-4 Customer-specific
Figure 9: Container stacker Switch outputs 2 - 18 0-1
Communication CAN, RS232 CAN, diagnosis
Voltage 12 - 24V 12V
Implementing the CAN strategy - Typ of Protection IP65 IP54
The modular systems of Rexroth (max. IP66)
mobile electronics
Without a doubt, the control unit is at
the very heart of the electronics. But
our product range would not be com-
plete without our sophisticated peri-
pherals: the sensors, control transmit-
ters and diagnostic units. The Rexroth
hardware modular system consists of universal control unit special control unit customer-specific control unit
fully coordinated components, sup- RC2-2 EHR-C EFR2
plemented by a range of parameter as- Figure 10: Control units
signment and diagnostic tools, the
BODAS development environment
and library of software functions that the Bosch SKE series, which has pro- field is achieved by extensive protec-
are described below. This modular sy- ven its worth millions of times over in tion against electrical faults. The units
stem is based on the current Rexroth both cars and trucks. The units are are suitable for both 12V and 24V. All
range of hardware. ideally suited to the harshest mobile the control units can be programmed
conditions, as demonstrated by an ex- by the customer using the BODAS
A) Control units tensive range of tests. programming system.
Working side by side with Bosch, Rex- The number of proportional outputs
roth has refined the MC series of con- ranges from two to twelve. Each con- We have the optimum solution for
trol units that has proven its worth in trol unit also has at least the same every type of customer:
the field for many years. The result of number of switching outputs. Simple – There are cost-effective universal
this joint venture is the new RC series communication and diagnostics are control units from the RC series for
of modular universal control units. made possible by the CAN bus and one-off projects to medium-sized
There are currently four sizes, which RS232 supplied as standard. Pro- production batches
differ according to the number of in- grammable multi-function inputs al-
puts and outputs. The mechanics of low maximum flexibility in terms of
the housing and plugs are taken from applications. High reliability in the
Bosch Rexroth AG
– For applications with larger produc-
tion runs, we can supply special
control units specifically tailored to
the particular application
– For large-scale users, we can provide
access to expertise in the develop-
ment and production of customer-
specific control units together with
Bosch
B) Sensors
If we describe control units as the he-
art of the electronics, then the sensors
are the sensory organs that mobile
machiness need to detect the path,
angle, travelling speed, speed of rota-
tion, pressure, temperature, accelerati-
on and other important parameters.
Reliable and fast signal conditioning
for various measured variables means
that we can now implement complex
circuits for controlling vehicles and
workflows. This helps to increase safe-
ty and comfort.
By joining forces with Bosch, we now
have access to sensors already de-
veloped in the field of automotive
equipment. These sensors are produ-
ced in very large numbers and to a
very high level of quality on automa-
tic serial production equipment. This
guarantees cost-effective standards for
a broad market and with little va-
riance. For new developments, we can
also leverage the potential of Bosch
research for sensors, where the em-
phasis is placed on developing new
and innovative sensor technologies.
These sensors are used throughout the
entire spectrum of mobile applicati-
ons.
Mobile Elektronics
Figure 11: Sensors
The following list contains a few ex-
amples:
– Fan control for buses and trucks
– Temperature control for internal
combustion engines (all load ran-
ges)
– Electronic accelerator pedal
– Swivel angle detector
– Electro-hydraulic hitch control in
tractors
– Electro-hydraulic header height
control for combine harvesters
– Speed measurement in pumps
– Speed measurement in transmissi-
ons
– Speed measurement in wheels
– Pressure measurement in hydraulic
systems
– Front pressure control in tractors
– Use in safety systems
– Measurement of steering angle and
steering speed
- Steer by wire
Mobile 2003 25
– Speed
– Temperature
– Pressure
– Angle
– Draft
– Steering angle
C) Control panels
Today, the working hydraulic move-
ments of mobile machines are gene-
rally controlled using joysticks. Moni-
toring and parameter assignment
functions are realized using displays.
Rexroth supplies both standard joy-
sticks and units customized for special
applications. Both are based on the
proven standards described above.
The standard joystick, e.g. for con-
struction machinery,:
There are three versions of the 4THE5
with its well-known Ergo handles, the
EC2000, EC3000 and the recently de-
veloped EC4000. It is a robust unit
that is particularly suitable for the
harsh conditions of construction ma-
chinery, for example. The available in-
terfaces are analog signal, CAN bus
and power output for directly con-
trolling valves (see fig. 12).
26 Mobile 2003 Mobile Elektronics
Figure 12: 4THE5
The most important technical data:
– Signal version: Voltage output 0.5 to
4.5 V
– CAN version: 11-bit identifier and
compatible with 2.0A and 2.0B
– Power version: PWM output up to
2.6 A
The joystick specialist, e.g. for fork-lift
trucks:
Our system is based on a basic unit
with standardized electronics and me-
chanisms, supplemented with the ap-
plication-specific handle. Non-con-
tact Hall sensors and conversion of
the signals for the CAN bus are the
consistent technical principles. The
joystick head is individually designed
so that it can be matched to specific
customer requirements. A clever tech-
nical solution also allows the opera-
ting forces to be mapped very indivi-
dually, as in a characteristics map.
The most important technical data:
- Redundant sensors for the x/y axis
- Up to 4 analog inputs and up to 8
switching inputs
- Suitable for 12 V and 24 V vehicle
electrical systems
- Adaptation of characteristic curves
using the software
Bosch Rexroth AG
For the display, we now supply the re- ly robust service tool for working di-
cently-developed, robust standard DI2 rectly on the machine. It communica-
unit. tes with the control unit via the pro-
It was developed especially for use in ven RS232 standard interface. All the
mobile machines, even outside the relevant parameters appear as clear
driver’s cab. text in multiple languages on the dis-
play. Operator input is menu-driven,
and data is entered via a robust mem-
brane keyboard.
The BODEM software is available for
user-friendly diagnostics and parame-
ter assignment. It can display several
process variables (e.g. speeds or cur-
rents) at the same time. The data log-
ger function can be used to record
process variables over time and plot
them on a curve in order to check the
machine’s behavior. Several control
Figure 13: Display DI2
units can be easily adjusted by trans-
ferring whole parameter sets.
It has the following special features:
– High degree of protection, with
IP69K at the front and IP65 at the
back
– CAN bus interface
– Backlight
– Real-time clock
– Suitable for 12 V and 24 V vehicle
electrical systems
– Representation of process variables,
pictograms and error messages
– Customized screen layout Figure 14: Control panel BB-3
– Excellent user guidance with soft-
keys
D) Diagnostic tools
Comprehensive diagnostic functions
and easy parameter assignment for
control units are an absolute priority
today. Rexroth supplies two standard
tools for this purpose.
The BB-3 control panel is an extreme-
Figure 15: Software BODEM
Bosch Rexroth AG
Building block 5:
The software - Off-the-
shelf application modu-
les, customer-specific
development environ-
ment or individual ser-
vice
If complete turnkey solutions are nee-
ded for hydraulic applications, then
Rexroth has various approaches ready
for use. From various levels of stan-
dardization, customers can choose
between complete templates or custo-
mized programming. Partially stan-
dardized solutions are also supported
with off-the-shelf modules and basic
functions. These all have a common
basis: BODAS - a tool exclusive to
Rexroth that is used as a development
environment and programming sy-
stem for mobile electronics.
Figure 16: The easy route to application software for the mobile machine
Mobile Elektronics
A) Programming with BODAS -
almost without limits
BODAS with its programming lan-
guages conforming to IEC 61131 of-
fers a complete, professional software
development platform for the ambi-
tious application programmer. It uses
the benefits of graphical representati-
on to describe workflows, create se-
quential function charts and ladder
diagrams and write text-oriented pro-
grams (structured text). In addition to
this basic functionality, BODAS also
provides other functions such as:
– Operating system functions for the
RC control units, e.g. for inputs/
outputs, teach functions, speed
measurement, etc.
– CAN bus communication
– Display support
– Integration of diagnostic functions
with BB-3 and BODEM
– BODAS-LIB library with software
modules for basic functions (RD
95111)
Mobile 2003 27
For complex software structures, BO-
DAS’ particular strengths are graphi-
cal representation and hierarchical
structuring. One example of this is
the status diagram for the various
operating states of a vehicle, with a
large number of logical operations.
If even the ambitious limits of
BODAS are reached, then the high-
level „C“ language can always be used
as an alternative. Examples of this are
when extremely time-critical operati-
ons have to be controlled by inter-
rupts or the space required for gene-
rated code has to be minimized.
B) The fastest way to the solution
- programming with templates
and modules
Templates are off-the-shelf applicati-
on programs for controlling entire
mobile hydraulic implements. No spe-
cial software is programmed. Instead
the program is fine-tuned for the par-
ticular application by changing the
parameter settings. Or the template is
used as a software template for adap-
ting the programming.
With the template, the programmer
receives working software the structu-
ring and coding of which conform to
the Rexroth programming guidelines.
This ensures that the software is both
functionally reliable and effective. It
also forms a basis for quickly and easi-
ly exchanging programming experi-
ence and software.
28 Mobile 2003 Mobile Elektronics
One example of these BODAS tem-
plates is the FGRA template for pro-
gramming travel drives for municipal
vehicles. It performs the following
functions:
– Automotive driving
– Changing the direction of travel by
reversing
– Variable reduction of driving speed
by inching
– Diesel engine speed limitation with
teach function
– Load limiting control for the diesel
engine
– Constant-speed drive with open or
closed-loop control
Figure 17: Municipal vehicle
Building block 6:
Application knowledge
for the complete system
solution
Rexroth uses its extensive application
knowledge to implement a complete
system from all the hardware and
software components described abo-
ve. At our many application centers
around the world we gather experi-
ence with the design of complete im-
plements - creating a massive fund of
knowledge that can be used to the be-
nefit of every customer. We develop
our in-house expertise with our elec-
tronic specialists who, of course, can
be found at all of these application
centers. Finally, we pass this know-
ledge on to our customers.
What are the benefits of these applica-
tion skills to our customers?
The very term „mobile machine“ indi-
cates that the emphasis is placed on
the combination of transportation,
loading and unloading. This requires
all the components that make up the
technology in the machine to interact
perfectly in order to meet the require-
ments safely, reliably and cost-effec-
tively. The technology in your machi-
ne is the determining factor in the de-
velopment of our products, so we de-
velop our own staff so that they learn
the skills they will need for each appli-
cation. The example of a field sprayer
below represents a comprehensive sy-
stem solution that was brought to the
prototyping stage at our own applica-
tion centers.
Figure 18: Acricultural sprayer
Bosch Rexroth AG
Building block 7:
Services for customers,
from planning to com-
missioning into service
This building block is certainly one of
the most important for the success of
our electronics strategy. We work alo-
ngside our customers from the very
first concept meetings with our ex-
perts right through to supporting
their own end customers as the vehic-
les are used under harsh conditions,
year after year:
A) Hand in hand project work
The most important steps on the way
to successful serial production inclu-
de:
– Support in drawing up the custo-
mer specification
– Creation of the project specification
by our experts, followed by confir-
mation from the client
– Development using modern draf-
ting techniques in consultation with
the customer
– Laboratory function tests and trials
to stringent Bosch standards
– Commissioning and fine-tuning on
the prototype machine
– Series production release based on
the customer specification
B) Worldwide expertise
Of course, all the tasks are carried out
on the basis of professionally planned
and monitored processes. The basic
principles are our strict quality and
environmental standards, combined
with the current safety directives.
Worldwide network of application
Bosch Rexroth AG Mobile Elektronics Mobile 2003 29

specialists: The Rexroth worldwide sa- 2. Our goal for your

les organization is available as a con-
tact to bring your ideas to fruition. In
software development, programmers
from the „local“ national companies
work very closely with central soft-
ware development at the home plants.
In this way, we can offer both the top
skills and a rapid response to your re-
quirements from closer to home.
If the customer decides to develop the
software himself, then we can offer ex-
pert application support in addition
to powerful tools. Even joint software
development is possible, and has al-
ready been completed successfully in
several projects.
future
Rexroth regards the seven building
blocks described here as the essential
basis for the success of our customers.
With our experience and the latest
technology, we can guarantee our cu-
stomers access to leading edge of tech-
nology for their hydraulic machines.
This is our primary goal for the fu-
ture.

C) Service for decades

We are still there for our customers,
even years after producing and supp-
lying our serial products. Of course,
the Bosch Rexroth Service takes re-
sponsibility for the electronics as for
all other products. We therefore gua-
rantee spare parts and offer on-site
service over a long period.
30 Mobile 2003 Mobile Elektronics Bosch Rexroth AG