20 Mobile 2006 BODAS Bosch Rexroth AG
Costs
The development time and costs associated with a machine can be con-
siderably reduced through the use of the BODAS system from Rexroth.
When using a BODAS standard software package, an off-the-shelf
electronic machine control can be used.
Function
The BODAS hardware and software modules contain extensive safety
and diagnostic functions. Through the use of these functions, dangerous
machine operating conditions can be detected in good time and appro-
priate safety measures taken to eliminate hazards to personnel.
Bosch Rexroth AG BODAS Mobile 2006 21
BODAS The System for Mobile
Electronics
Manufacturers of mobile equipment face great challenges: On the one hand,
the market demands higher development speeds at lower costs. On the
other, the products must functionally stand out from the competition in order
to be successful. As with automobiles, end users place increasing demands
on the availability and the comfort of the machine. Moreover, legislation in all
relevant markets is constantly sharpening product liability and certification
regulations. In front of this backdrop, a rapid shift is taking place from purely
hydraulically controlled machines to those which are partially or fully electro-
nically controlled. Only through the use of electronics can these apparently
contradictory demands be fulfilled.
Claus von Reibnitz
Elchingen (D)
22 Mobile 2006 BODAS
1 Why use electronics in
mobile equipment?
In the past, purely hydraulic or me-
chanical systems could satisfactorily
perform many functions in mobile
equipment. Now, however, even the
current emission limit values for e.g.
diesel engines according to EURO 4/5
or Tier III (USA) can only be met us-
ing electronically controlled injection
systems. Hydraulic and mechanical
systems can generally only be opti-
mized for one operating point. The
machine behavior at other operating
ranges is a compromise. Through the
use of electronic systems, the machine
can operate optimally with character-
istics or operating maps under a va-
riety of operating conditions. For ex-
ample, the assignment of variable fine
control ranges of the working hydrau-
lics when using various attachments.
The increased quality requirements
on the performance of a machine urge
the automation of functions in order
to reduce or eliminate the effects of
human fatigue during the workday.
The automatic parallel guidance of
the bucket in wheel loaders is a step
precisely in this direction. New, in-
novative functions often require
the use of electronics. With BODAS
controllers, Rexroth implemented the
automated shift on fly gear-shifting
solution which, when compared to
conventional power shift transmis-
sions, is a particularly economical and
easy-to-use solution.
Bosch Rexroth AG
Fig. 1: BODAS System.
2 Fast implementation of 2.1 BODAS controllers
The BODAS controller range consists
machine functions
of seven RC controllers matched to
For the fast implementation of com-
the needs of the respective machine
plex machine functions, hydraulics
and a CAN I/O-extension module
offer a broad range of modules which
RCE. The functional scope of the con-
can be specifically optimized and
trollers extends from the control of a
adapted to the given machine. The
single hydraulic pump or valve slice
same procedure has also proven itself
to complete vehicle management. The
in the implementation of electronical-
fine scaling of the functional scope
ly controlled functions. As a require-
makes possible a cost-optimized selec-
ment, Rexroth has developed a flexible
tion which is suitable for the given
and modular range of products with
application, without unused control-
mutually coordinated interfaces. Soft-
ler resources. All controllers use a uni-
ware modules with predefined func-
form concept which consists of com-
tionality and modular structure are
ponents that have proven themselves
also available for this hardware. Thus,
at Bosch in motor vehicle applications
the BODAS system includes scalable
a million times over in daily use. De-
hardware and software components
velopment departments at Bosch have
with the corresponding development
also tested and released them for the
and diagnostic tools. This system, in
more demanding mobile application
which all components are matched to
conditions. This ensures constant and
one another, makes possible extremely
long-lasting, reliable function even
fast and economical implementation
under extreme environmental condi-
of machine functions.
tions when used in mobile machines.
Bosch Rexroth AG BODAS Mobile 2006 23

The controllers fulfill protection type

IP65. Plug systems and pin sizes make
possible problem-free assembly even
under difficult application conditions.
All controllers are equipped with
processors of the C167 family, which
can be clocked at up to 40 MHz. Thus,
they can even be used for the imple-
mentation of dynamic pressure con-
trols of multiple axes . Through the
use of a uniform application interface,
application software can easily be
transferred from one controller size to
another. This simplifies, for example,
the integration of additional functions
in an existing control system.

Safety concept
The BODAS controller RC is
equipped with an extensive, integrated
safety concept which, if necessary,
permits their use in applications even
in safety critical areas up to SIL2 (IEC
61508). The decisive requirement is
that the controllers must detect criti-
cal errors and safely control the corre-
sponding machine function. For this
purpose, the BODAS controller RC
provides the function for redundantly
reading in sensor signals or setpoints
via separate circuits. The controllers
check the plausibility and process only
the error-free signals. In combination
with the electronic THE5C joystick
with CAN bus interface, the RC con-
troller can ensure safe data trans-
mission according to SIL2 through
a process which has been registered
for patent by Rexroth, even without
a redundant CAN bus or additional
analog signal. Monitoring of the
processor is performed by a special
Bosch watchdog module. It monitors
Fig. 2: BODAS Controllers RC.
the proper program execution and data remain available even while the
exchanges computational results with machine in this state.
the controller during program execu-
tion at defined time intervals. The
operating system software cyclically
monitors the processor and the mem-
ory modules for error-free function.
Through direct access to the central
power switch, which is located in the
controller, the outputs to the hydrau-
lic control can be switched off if the
computational results do not arrive
at the correct time or do not have the
correct result. The software can then
use this switch to place the machine
in a safe state (fail-safe), thereby pre-
venting the malfunction from posing
a danger. The computer remains acti-
vated in this case. Thus, the diagnostic
24 Mobile 2006 BODAS Bosch Rexroth AG

Rexroth ERGO handle bars of the EC

2000-4000 series offer functionality
which ranges from a simple button
to the integration of additional axes.
Thus, it is very easy for the manufac-
turer to implement individual user
designs. The BODAS compact joy-
stick EJ is available for applications
in which the installation space of the
base is particularly limited. Function
and handle bar adaptation are identi-
cal to the THE5. Software and user
concepts are the same when changing
Fig. 3: SIL2 Concept THE5C. from the THE5 to the EJ. Thus, it is
easy to transfer user concepts between
various machine sizes.
2.2 Modular BODAS application 2.3 BODAS user interface
software Operation and user concepts are as
Many machine functions are based on individual as the given machine. The
a number of basic functions. Essential THE5 electronic BODAS joysticks are
basic functions in machines include, characterized by a particularly robust
for instance power management for construction which has the same
pumps, the control of hydrostatic look and feel as hydraulic joysticks.
fans and auxiliary drives, the drive
of wheel- and chain-driven vehicles,
gearbox controls as well as the con-
trol of valves for operating functions.
These basic functions are included
in the BODAS software module as
parameterizable function modules.
In the simplest case, the controller
contains these functions in the off-
the-shelf standard software. The
standard software contains a number
of well thought-out functions. The ac-
tivation and fine tuning of these func-
tions give the machine its individual
characteristics without the need to
spend additional time changing the
software. Through defined interfaces,
Rexroth can easily and quickly per-
form extensions and combinations
with additional functionality.

Fig. 4: BODAS Joystick EJ and THE5.

Bosch Rexroth AG
2.4 BODAS sensors
The extensive range of BODAS sen-
sors offers special sensors for all es-
sential measurement tasks. The uni-
form interface to the BODAS control-
lers for analog signals simplifies the
connection of various sensors to the
controller. In addition to the actual
measurement signal, BODAS sensors
also supply information which can be
used to provide better diagnostics of
the sensor state. The DSM1-10 speed
sensor supplies information on the
speed and direction of rotation via a
coded two-wire interface. Through
this coding, it provides additional in-
formation about the spatial position
of the sensor to the measurement gear
wheel. As result, the application soft-
ware of the controller can determine
in good time whether the position
of the sensor has begun to change.
Conventional speed sensors use two
90 degrees phase-shifted rectangular
signals to detect changes in direction.
Using this method it is not possible to
reliably detect whether a ground/bat-
tery short-circuit of a sensor line has
occurred while at a standstill. Even
while at a standstill, BODAS speed
sensor DSM1-10 constantly supplies
a life signal. As a result, it is pos-
sible for the controller to detect, for
instance cable damage even before the
machine is started and, thus, prevent
dangerous machine states through the
detection of the missing speed signal.
BODAS Mobile 2006 25
Diagnostic tool: BODEM
With the BODEM diagnostic tool,
service employees and employees per-
forming the commissioning can very
easily make changes to the parameter
settings in the software. No program-
Fig. 5: BODAS Speed Sensor DSM1-10. ming knowledge is necessary in order
to make these changes: the software
developer has already predefined ac-
2.5 BODAS tools
cess to the individual parameters. The
Development tool: BODAS-design critical parameters are protected by
Standardized programming languages password and can only be changed
simplify fast and high-quality software by authorized personnel. BODEM
creation. Using the BODAS-design allows parameter reset to the stored
software development tool, users can factory settings at any time. As a re-
create software in accordance with sult, it is easy to restore machine func-
international standard IEC 61131 in tions even if settings are accidentally
a variety of languages. The developer changed.
can implement parts of the program
differently depending on the applica-
tion for which the software is to be
used, for example in structured text
or function plan. The graphical user
interface ensures an excellent over-
view here. This interface automati-
cally generates documentation for the
software which is just written. This
considerably simplifies subsequent
changes and maintenance of software.
The integrated debugger fully tests the
software on the bench. This function
considerably reduces the commission-
ing time of the machine.
26 Mobile 2006 BODAS Bosch Rexroth AG

2.6 Example: BODAS VAC stan-

BODAS Controller RC6-9
dard software with VACC software
A number of variants of the BODAS
VAC (VAlve Control)standard soft-
ware for valve management are avail-
able depending on the number of
valve slices which are to be controlled.
A wide variety of joysticks can easily Safety-
be integrated through parameter set- switch 2
Safetyswitch 1
tings. A mouse click is all it takes to
conveniently adjust the CAN protocol Switched input

for the Rexroth THE or EJ joystick. CAN bus

Joystick interface
The selection of the CAN address for
the respective joystick concludes this Error lamp
Endswitch A/B
process. Rexroth designed the selec- Compression factor
Switched outputs
tion of the corresponding CAN-based 16
Direction switches A/B
Rexroth valves (e.g. SB23LS or M4- DRE A/B
Connections per
OBE) just as simply. For analog con- movement axis
trolled Rexroth valves (e.g. M4, M6,
M7), a few mouse clicks are all that is
necessary to select the necessary set
values. The specific behavior of the
machine is determined by means of
several ramp times and characteristic Variable or fixed Control block
curves, which can be individually and pump SB 12 LS or
SB 23 LS or
flexibly adjusted by means of param- SP08 or
eters, without requiring the program- M412/15/22 with DRE02 or
mer to make changes to the software. M615/20/22 with DRE02 or
M720/22 with DRE04
Even additional functions, such as
counter operation for rapidly stop- Fig. 6: System concept BODAS Valve management VAC.
ping a movement or for unloading an
excavator bucket, can be selected by
and flexibility of the provided solu-
the user. The transmission via CAN
tions, is an economical and extremely
bus of all important variables and
fast off-the-shelf solution for a wide
status values is enabled with a single
variety of applications.
activation parameter. The CAN mes-
sages are picked up by the BODAS
display DI2 and shown on the graphic
display. This display is also used to
perform all settings of the standard
software without the need for an ad-
ditional PC or handheld diagnostic
tool. Rexroths VAC standard software,
with its high degree of adaptability
Bosch Rexroth AG BODAS Mobile 2006 27

3 Conclusion
BODAS consists of a complete range
of modules which include all com-
ponents necessary for electronically
controlling machines. All interfaces
are matching within the BODAS
system and are compatible with
Rexroth mobile hydraulics. With the
BODAS system, manufacturers can
easily, quickly and, thus, economi-
cally implement machine functions.
For machines with a high number
of proportional movements which
are to be controlled, the dynamics
are limited by 16-bit processors. For
these applications, Rexroth will, in the
future, be using the Infinion Tricore
TS1796 on a 32-bit computer which
has already found broad acceptance in
the automotive industry. It utilizes a
single-channel computer architecture
to satisfy even increased safety re-
quirements according to SIL2.