Application software BODAS-drive DRC

Application software

BODAS-drive DRC

RE 95323

Edition: 10.2015

▶ Control solution for hydrostatic drivetrains

▶ Release 41

Features

▶ Covering a wide range of hydrostatic drivetrain and

gearbox variants of wheeled mobile machines

▶ Load sensitive and automotive driving for load and travel operations

▶ Proportional driving at fixed engine speed for work and material handling operations

▶ Multiple comfort functions like cruise control or velocity limitation for accurate and easy driving.

▶ Diesel Hydraulic Control ECOdrive and ECOwork for improved efficiency and reduced noise emissions

▶ Flexible interfaces – discrete or CAN J1939

▶ Comprehensive configuration options via BODAS-service

▶ Integrated safety functions in accordance with EN ISO

13849 and ISO 25119

▶ Modular software concept for efficient customer-specific extensions

▶ Supporting process documents and tools for systematic integration into the machine

▶ BODAS-drive DRC is part of BODAS Bosch Rexroth design and application system for mobile electronics

▶ Software solution on Rexroth controller RC12-10/30

Contents

1 Introduction

2 Typical applications and variants

3 System description

3.1 System overview

3.2 Drivetrain components

4 Functional description

4.1 Driving functions

4.2 Comfort functions

4.3 Energy efficiency and component protection

functions

5 Electrical interfaces

5.1 Connection diagram RC12-10/30

5.2 CAN signals

5.3 Inputs

5.4 Outputs

5.5 Power supplies

6 Functional safety in accordance with

EN ISO 13849 and ISO 25119

6.1 Approach

6.2 Concept

6.3 Safety functions 26

6.4 Example of using a BODAS-drive safety function 30

7 Project engineering and ordering information 32

25

25

25

17

22

24

10

11

12

16

7

8

9

4

6

7.1 Ordering code

8 Valid standards and separate documentation

9 Abbreviations

10 Safety Instructions

2

2

4

33

34

35

36

RE 95323/10.2015, Bosch Rexroth AG

2 BODAS-drive DRC | Application software

Introduction

1 Introduction 2 Typical applications and variants

BODAS-drive DRC is a software solution embedded in

Rexroth controller RC12-10/30 to control hydrostatic drivetrains of wheeled vehicles. BODAS-drive covers a wide range of drivetrain types. The drivetrain is always based on an engine with CAN interface and a hydrostatic drive consisting of a pump and at least one motor. The gearbox type can vary between fixed gears, a gearbox shiftable during standstill, a shift-on-fly gearbox, a summation gearbox or radial piston motors mounted at the wheels.

The load sensitive travel behavior and features like automotive driving, hydrostatic braking and reversing provide for accurate and easy driving of the mobile machine. Proportional driving at a fixed engine speed can be the right choice for work and handling operations. The integrated

Diesel Hydraulic Control DHC ECOdrive and ECOwork functions reduce fuel consumption and noise emissions.

Comfort functions like cruise control, hand throttle, speed limitation and the automatic parking brake support the driver at the daily work. The comprehensive diagnostics and well-defined limp-home strategies ensure that the machine is operational.

BODAS-drive is designed to control the hydrostatic drivetrain of wheeled mobile machines. Thanks to the multiple functions and configuration options it can be adapted to various applications. Typical examples include wheeled loaders, telehandlers, dumpers, municipal vehicles and fork lift trucks. BODAS-drive was developed using a generic approach and represents a Safety Element out of Context

(SEooC). Assumptions have been made and documented accordingly for the applicable safety functions of BODASdrive.

Note

BODAS-drive helps to realize functionality and safety at the machine level. The machine manufacturer must thoroughly check whether the functionality of BODAS-drive can fulfil the requirements of the specific machine. If additional features are required, BODAS-drive can be extended. Please consult your Bosch Rexroth contact for an individual solution.

Each input device can either be discretely connected to the

RC or the signal can be received via CAN. The BODAS-drive

CAN protocol is based on SAE J1939. BODAS-drive can be configured and adapted to the specific machine requirements by setting parameters with BODAS-service.

The BODAS-drive configuration is always based on an engine with a standard CAN J1939 interface and a Rexroth axial piston variable pump A4VG with electrical direct control type ET or electrical proportional control type EP.

Depending on the secondary side of the hydrostatic drive and the gearbox type, different configurations of BODASdrive are applicable.

Ready-to-use safety functions developed in accordance with the standards EN ISO 13849 and ISO 25119 are part of the software.

Documents and tools support a systematic integration of BODAS-drive within the machine environment from project planning to the start of production and beyond.

The software is created with a modular design that allows for efficient customer-specific extension. For more information about customer-specific extension, please consult your

Bosch Rexroth contact.

Bosch Rexroth AG, RE 95323/10.2015

Application software | BODAS-drive DRC

Introduction

3

BODAS-drive DRC

DRC variant

Engine

Hydraulic drive pump

Sensors

Driver interface

BODAS controller

Safety standards

A

Communication via CAN J1939

A4VG.ET or EP

(pump equipped with pressure and swivel angle sensors are mandatory for prototype machines!)

Discrete

Discrete or CAN J1939

RC12-10/30

EN ISO 13849, ISO 25119

Gearbox

Hydraulic pump

ET or EP

Fixed gear ratio, not shiftable

Up to 3 gear ratios, shiftable during standstill.

2 gear ratios shiftable during driving

1 hydraulic motor with

Standstill shifting gearbox or Shift-on-fly gearbox

MCR motors, displacement shiftable during standstill and during driving

Summation gearbox with one clutch interfacing

2 hydraulic motors for high torque and high speed

Power / speed range

2 hydraulic motors with

2+1 summation gearbox

Up to

4 hydraulic motors

1 hydraulic motor

Hydraulic drive motor(s)

1x A6VM.EP

1) or A6VM.HA variable displacement

1x motor with fixed displacement

Hydraulic drive motor(s): up to 4 shiftable MCR radial piston motors

(100% / 50% / 25% torque)

2x A6VM.EP

2) variable displacement

1x A6VM.EP

2) variable displacement and

1x motor with fixed displacement

1x A6VM.EP

2) variable displacement and

1x A6VM.HA variable displacement

1)

2)

Control type EP mandatory for Shift-on-fly gearbox.

The motor that can be disengaged (temporary motor) must be of type A6VM.EP, positive control recommended.



System description

3 System description

3.1 System overview

▼ System overview for a BODAS-drive DRC configuration with gearbox shiftable during standstill / shift-on-fly

Machine

ECU

Inputs via J1939 (optional)

BODAS-service

CAN

CAN1: BODAS-service

CAN2: SAE J1939

CAN3: free

CAN4: CCP

Transmission ECU

BODAS controller

RC12-10/30

+

BODAS-drive

ASrun DRCA41

CAN

SAE J1939

Engine

ECU

Diesel engine

Variable pump

A4VG ET or EP

CAN

Cable harness TCU

Variable motor

A6VM EP

Gearbox

BODAS

Display

CAN

Rear

Parking brake valve


▼ Part of system overview for a BODAS-drive configuration with summation gearbox


System description

5

▼ Part of system overview for a BODAS-drive configuration with radial piston motors MCR

Rear

Parking brake valve

2x

Variable motors

A6VM

2+1

Gearbox

The drivetrain consists of the following main components:

▶ BODAS controller RC + BODAS-drive DRC

▶ A combustion engine with its ECU + standard J1939

CAN protocol

▶ A variable hydraulic pump

▶ At least one hydraulic motor – fixed or variable

displacement

▶ A gearbox – design depends on the drivetrain

configuration

Various driver and machine interfaces can be installed, depending on the hardware configuration and desired functions. Each input can either be discretely connected to the RC or the signal can be received via CAN. The figures above show assembly examples of the involved components. For diagnostics and commissioning BODAS-service can be connected.

See Rexroth data sheet 95086 for a detailed description of

BODAS-service functions.



System description

3.2 Drivetrain components

Engine

A precondition for BODAS-drive DRC is a diesel engine equipped with an ECU supporting CAN SAE J1939. The engine ECU performs the complete control of the engine actuators and peripherals. A target speed request is set via

BODAS-drive. Actual engine values like speed or temperature are provided by the engine ECU. Important CAN messages are EEC1, ET1 and TSC1.

Drive pump

The A4VG is an axial piston pump in swashplate design with variable displacement and all components for a hydraulic closed circuit. The ET control module is a load sensitive control system.

The output flow of ET pump is infinitely variable between

0 to 100 %. Depending on the preselected current at solenoids a and b of the pressure-reducing valves, the stroke cylinder of the pump is proportionally supplied with control pressure. The pump displacement that arises at a certain control current is dependent on the speed and operating pressure of the pump. A different flow direction is associated with each pressure reducing valve.

Gearbox

Depending on the drivetrain requirements, such as maximum speed and tractive effort, there are various configurations available.

▶ Fixed gear ratio, not shiftable

▶ Up to 3 different gear ratios, shiftable during standstill and up to 2 gear ratios for shift-on-fly gearbox shiftable during driving. For gear actuations up to 3 switched outputs may be used. The combination for each active gear can be individually configured.

▶ Summation gearbox interfacing 2 hydraulic motors for high torque and high speed.

It provides high torque at low speed using both hydraulic motors and high speed through declutching one hydraulic motor under load without interrupting traction.

▶ Wheel mounted radial piston motors (type MCR) shiftable during standstill and shiftable during driving. For gear actuations up to 3 switched outputs may be used.

The combination for each active gear can be individually configured.

Note:

In any case the gearbox manufacturer must grant an approval for the operation of the respective gearbox type with BODAS-drive DRC.

The EP control module is a load independent control system.

The output flow of the EP pump is proportional to solenoid current and the pump speed.

For a detailed description of the pump A4VG see Rexroth datasheet 92004.

Drive motor

There is the possibility to apply fixed or variable hydraulic motors in the drivetrain. In case of a fixed motor the output speed of the hydraulic motor is proportional to the pump output flow. If the drivetrain is equipped with a variable axial piston motor A6VM with electric proportional control

EP, the hydrostatic ratio can additionally be controlled by an electrically defined signal which sets the swivel angle of the motor. The closed loop EP control system ensures a constant swivel angle independent from the occurring high pressure.

For a detailled description of the motor A6VM see Rexroth datasheet 91610.



Functional description

7

4 Functional description

BODAS-drive evaluates the input signals coming from the connected operator devices and machine sensors. Based on this, BODAS-drive calculates the control values for the various actuators, such as the engine, hydrostatic drive and gearbox. To map the BODAS-drive functionality to a particular machine configuration, each function can be separately activated using BODAS-service. Thus only the relevant inputs are evaluated and just the needed outputs are activated. The diagnostic routines are adapted with regard to the activated functions.

Operator devices

Machine sensors

Evaluation Sensitivity Dynamics

Driving functions

Automotive driving

Proportional driving

Pump control

Motor control

Engine speed control

Reversing

Service brake influence

Inching

Gearbox shifting in standstill

Gearbox shift-on-fly

Gearbox control for summation gearbox

Shift radial piston motors

Comfort functions

Velocity limitation

Cruise control

Tractive effort limitation

Hand throttle

Drive modes

Brake lamp control

Parking brake control

Diagnostics and fault lamp

control

Limp-home mode

Energy efficiency and component protection functions

DHC ECOdrive

DHC ECOwork

Load limiting control drive

Engine overspeed protection

Temperature range protection

Power limitation

Safety functions

Safe standstill

Safe reversing

Safe drive direction

Safe speed limitation

Safe deceleration

Safe acceleration limit

Safe deceleration limit

Safe parking brake

Safe brake light

Safe operator detection

For a detailed description of the safety functions, see chapter 6.3.

The minimum configuration for operating devices requires a drive direction lever (FNR) and a drive pedal. With respect to sensors, it is expected that at least one speed sensor is installed to read the hydraulic motor or gearbox speed, which enables elementary drive functionality.

For a detailed description of the relationship between desired functions and required devices, see chapter 5.




4.1 Driving functions

Automotive driving

By using the drive pedal or the drive potentiometer, the driving function increases the engine speed and the hydrostatic ratio at the same time. This function provides a comfortable driving mode so that it feels like driving a car.

Proportional driving

By using the drive pedal or the drive potentiometer the driving function increases the hydrostatic ratio independent of the engine speed. This function can typically be used for working operations.

Reversing

By using the drive direction switch or a drive pedal with direction signals the reversing function is able to decelerate and subsequently accelerate the machine in the new direction.

The reversing function works at any machine speed.

Pump control

In order to accelerate the machine from standstill the hydraulic pump is swiveled from zero to maximum displacement. Three different guiding modes can be selected for the pump control function:

▶ Actual engine speed

▶ Desired engine speed (proportional to drive request) and actual engine speed

▶ Desired engine speed (proportional to drive request)

In conjunction with the electro-hydraulic pump control ET, a hydraulic pump DA (speed-controlled) function can be emulated by using the actual engine speed as guiding signal.

Engine speed control

The engine provides power for the drivetrain and the implement hydraulics and, if requested, a fixed engine speed for certain working processes.

The driver has up to three different options to set the desired engine speed:

▶ Drive request (pedal and/or potentiometer)

▶ Hand throttle

▶ Implement request (DHC ECOwork mode)

Service brake influence

Evaluation of the mechanical service brake actuation is used to control the hydraulic pump back to zero displacement more quickly in order to prevent that the mechanical brake from working against the hydrostatic drive and thus to support the mechanical braking.

Inching

Using the inch pedal, the pump control can be reduced independently from the drive pedal position and the actual engine speed. The function allows a high fine controllability during working operations. Additionally the inching function can be used with a combined braking and inching pedal instead of a separate inching pedal.

Motor control

In order to do the secondary acceleration phase (pump does the first), the hydraulic motor has to swivel from its maximum to its minimum displacement. Four different guiding signals can be selected:

▶ Actual velocity

▶ Desired velocity

▶ Actual engine speed

▶ Desired engine speed

In conjunction with the motor pressure control function, a hydraulic motor HA (high-pressure-controlled) or DA

(speed-controlled) function can be emulated. Without motor pressure control the only reasonable guiding value is the actual machine velocity.

Motor pressure control:

The high pressure signal can be used to limit the maximum high pressure, for example, to prevent the engine from being overloaded. A further advantage is to keep the pressure below the hydraulic pump pressure cut-off limit. This function emulates hydraulic motor HA functionality.

Gearbox shifting in standstill

This function can be used to select one of three mechanical gears.

Changing from one gear to another is possible only when the vehicle is at a standstill. Pressing the shift-up and shift-down buttons requests shifting from neutral up to 3rd gear and back. A shift up request shifts up one gear and a shift down request shifts down one gear. For a gearbox with 2 gears (1st and 2nd) it is possible to use a single shift button.

Gearbox shift-on-fly

This function can be used to select one from up to two mechanical gears.

Changing from one gear to the other is possible when the vehicle is at a standstill and during driving. A manual and automatic mode is available. Pressing the shift button

(single shift request or shift-up / shift-down combination) requests shifting from 1st to 2nd gear and vice verca.




9

Shift radial piston motors

Up to three transmission ratios are supported: 100%, 50% and 25%. Changing from one ratio to another is possible during standstill and during driving. A manual and automatic mode is available. Pressing the shift button (single shift request or shift-up / shift-down combination) requests shifting from 1st up to 3rd ratio and back.

Gearbox control for summation gearbox

The summation gearbox management function provides a high torque range for working and a high velocity range for driving purposes. The transition between torque and velocity range is done fully automatically and without interruption of tractive effort.

Tractive effort limitation

For some working situations it is necessary to reduce the maximum tractive effort. With this function the driver is able to control the maximum torque at the wheels by using a proportional limitation request.

Hand throttle

For many working situations it is useful to set a fixed engine speed manually. For this purpose a proportional request signal can be used independently from using the drive pedal.

4.2 Comfort functions

Velocity limitation

Limitation to a maximum machine velocity is mainly used to meet country-specific speed limitation requirements.

This function also makes it possible to set different speed limits depending on drive mode, drive direction and error reaction modes.

The valid maximum limitation value is the minimum from all limitation sources (country, mode, direction, etc.).

The velocity limitation value can be reduced even more by using a proportional driver request signal. This is useful for meeting the most appropriate limitation for the current driving or working situation.

Moreover, a switch signal can be used to set a predefined velocity limitation value for safety reasons. It is useful when the velocity must be limited due to a certain action signaled by the machine. For example, if the working boom exceeds a certain limit. As soon as the position is reached, the machine automatically decelerates to the predefined limitation setting.

Cruise control

Once the cruise control switch is on, the cruise control function is activated by pressing the set button. Subsequently the machine is constantly kept at the current velocity without pressing the drive pedal.

The machine could be accelerated to a higher velocity by pressing the drive pedal. If the drive pedal is released again, the current machine target velocity is set back to the originally activated cruise control velocity.

Drive modes

Up to five different drive modes are selectable. Switching from one drive mode to another is allowed during driving.

For each of these drive modes the following settings are adjustable and selectable:

▶ Activation/deactivation of functions (e.g. ECOdrive, cruise control, etc.)

▶ Sensitivity (e.g. engine speed curve, pump curve, etc.)

▶ Dynamical behavior

(e.g. acceleration and deceleration, etc.)

Example mode definition:

▶ Mode 1: Street (Transportation)

▶ Mode 2: Handling (Material handling)

▶ Mode 3: Loader (Working mode)

Brake lamp control

The braking lights are activated if the deceleration exceeds a defined limit. An external activation of the brake lamp e.g. by pressing the brake pedal is still required and it is not part of BODAS-drive.

Parking brake control

The parking brake function provides two modes: manual and automatic mode.

Manual mode uses either buttons or switches to engage or disengage the parking brake.

Automatic mode engages the parking brake automatically as soon as the machine reaches a standstill. The brake disengages when the driver starts accelerating the machine again. The parking brake can still be manually engaged and disengaged in automatic mode.




Diagnostics and fault lamp control

The state of the control unit as well as the connected devices are monitored during operation.

If a fault occurs:

▶ An appropriate error reaction is activated, such as power off, ramp stop or limp-home.

▶ The severity of the fault is indicated via the blinking frequency of the fault lamp.

▶ Active and saved errors are reported via BODAS-service.

▶ Active errors (DM1) and previously active errors (DM2) are reported via CAN J1939.

Load limiting control

This function provides protection against overloading and stalling of the engine. The actual and desired engine speed is monitored. If the actual engine speed drops too much, the hydrostatic ratio is reduced in order to reduce the load on the engine.

During a high load situation (e.g. digging), the hydrostatic ratio has to be reduced rather quickly. Therefore the load limiting control works on the pump and the motors independently, or also simultaneously, if necessary.

Limp-home mode

▶ Limp-home mode 1: Driving is only allowed in one direction, forward or backward.

▶ Limp-home mode 2: Maximum velocity limitation is set to a limp-home speed.

4.3 Energy efficiency and component protection functions

DHC ECOdrive

The intelligent DHC ECOdrive control strategy adapts the engine speed request according to the needed power for driving. During acceleration or uphill-driving phases the engine speed request is increased. If less power is needed, the engine speed request is decreased. The hydrostatic drive is controlled accordingly to achieve smooth and dynamic travel behavior.

As a result, the machine behavior is similar to a full power mode setting, but with improved fuel efficiency and reduced noise emissions.

Engine overspeed protection

The diesel engine overspeed protection protects the diesel engine from damage caused by hydrostatic braking.

If the engine speed accelerates above the parameterized limit, the hydrostatic ratio is frozen and/or increased as long as the overspeed limit is exceeded.

In one option an external consumer (retarder valve) is controlled proportionally to the degree of engine overspeed.

Warning: To prevent the engine speed from increasing further and damaging the engine, the machine must be equipped with an adequate mechanical service brake which must then be actuated by the driver. It is recommended to install an additional acustic signal to inform the driver about the overspeed situation.

Power limitation

The power limitation function limits the power consumed by the drive pump. The function can be activated by switch.

The level of limitation is configurable.

DHC ECOwork

With this function the engine speed is kept at a low idle until a working request is detected. Subsequently the engine speed is increased depending on the DHC ECOwork request, which typically comes from the implement joystick.

Increasing the engine speed only upon receiving a working request contributes to improved fuel consumption and noise emissions while working with the machine.

If this function is active during driving, the increased engine speed is automatically compensated for by the hydrostatic drive.

Temperature range protection

The protection helps to prevent damage to the components hydraulic motor and pump caused by temperatures outside the defined range.

If the temperature gets outside the defined temperature limits, the engine/pump speed and or velocity (motor speed) is reduced.

The individual protection for these two components can be configured separately.



Electrical interfaces

11

5 Electrical interfaces

The modular approach of BODAS-drive enables a flexible activation of the available functions.

The table below describes the relationship between desired

Inputs


functions and required driver and machine interfaces for inputs and outputs.

Machine interface Driver

Outputs

Machine interface

Automotive driving

Brake lamp control

Cruise control

Diagnostics 3)

Drive demand

Drive modes

ECO drive mode

3)

ECO work mode


Engine overspeed protection o 6) o 6) x x x x x x o

6) o

6) o x o o o x x x o 4) x x x x x x x x x x x x x x x x x x x x x x x x x x o x x x x x x x x x x x x x x x

6) o 6) x x x x x x x x x x x x x x x x x x o 6) o 6) o

6) o

6) o 6) o 6) x x x x x o x x x

Inch function

Load limiting control

Motor control

Motor pressure control

Motor protection

Parking brake control o 6) o 6) o o x x x o x x x x x x x x x x o

Power limitation

Pump control o 6) o 6)

Pump protection

Radial piston motors (MCR) o

6) o

6)

Reversing function

Service brake influence o o

Shift-on-fly gearbox control o 6) o 6) o x

Standstill gearbox control

Summation gearbox control o 6) o 6)

Tractive effort limitation x

Velocity limitation control o x = mandatory for functionality o = optional (additional enhanced functionality) o x x o o x x x x o x x x x o x o x x x o o o 4) x x o x x x o x x x o x x x x x x x x x o x x 2) x 1) x x x x x x x x x x x x x x x x x x x x x x x x x x x x x o

Note

The detailed hardware characteristics of the RC controller are described in Rexroth data sheet 95204. This data sheet must be taken into account before implementing

BODAS-drive at the machine level.

1)

2)

3)

With summation gearbox (e.g. 2+1)

With standstill gearbox (up to 3 gears)

Diagnostics depends on enabled functionality

4)

5)

6)

Mandatory for close loop control

Mandatory for prototype machines

One option mandatory




Example: Engine overspeed protection

Engine speed input, Pump, Motor, Motor temporary outputs are mandatory.

Retarder valve output is optional.

Inputs

Driver interface Machine interface Driver

Outputs



Engine overspeed protection o 6) o 6)

Inch function x o 6) o 6) x x o x o x x x x x x o

5.1 Connection diagram RC12-10/30

Check for maximum output currents

The maximum allowed current per output pin is individually indicated in the connection diagram.

Within the ECU, one output stage drives the current for two output pins. The current sum of both pins must remain below the maximum allowed current of the output stage.

For additional information, also refer to Rexroth data sheet

95204 for BODAS controller RC series 30.




13

Connection diagram RC12-10/30, part 1

U

Bat

U

Ign

230

5 A

50 A

7)

3 A

3)

245

258

201

203

204

205

206

1 A

240

2 + 1 gearbox:

Speed sensor 1 at temporary motor

Speed sensor 2 at permanent motor

30

30 15

31

202

207

220

233

246

122

123

124

19)

Standstill/Sof gearbox:

Speed sensor 1 at gearbox input

Speed sensor 2 at gearbox output

Speed sensor

DSM, HDD2, DSA2 see page 15

Speed sensor

DSM, HDD2, DSA2 see page 15

Speed sensor

DSM see page 15

Speed sensor 1

Speed sensor 2

Pump speed sensor

(only Prototype)

1

2

1

2

1

2

112 IN_71

113 IN_72

110

IN_73

111 IN_74

109

IN_75

213 IN_66

208 IN_67

(shift up / single shift)

(shift down)

U

Pin 255, page 14

VSS_3

Drive mode switch 1 lgn

Pin 255, page 14

VSS_3

Auto shift enable

Drive mode switch 2

Drive mode switch 3

Drive mode switch 4

Drive mode switch 5

Poti

Poti

Poti

Poti

Velocity limitation request

Shift function A 1

Shift function A 2

Shift function B 1

Shift function B 2

Poti

Torque limitation request

Poti

Drive potentiometer

Neutral

Forward

Reverse

Poti

Drive pedal

Inch pedal

(combined brake/

Inch pedal)

Brake pedal

Engine hand request

Parking brake request 1

Parking brake request 2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

108

IN_68

133 IN_69

132 IN_70

134

211

144

1

2

Pin 119,

251 page 14 IN_40

247

234

225

212

248

237

239

224

143

142

235

IN_1

IN_2

IN_3

IN_4

IN_5

IN_6

IN_7

IN_8

IN_9

IN_10

IN_11

IN_12

IN_13

IN_14

IN_15

IN_16

IN_17

159

158

214

157

252

238

222

210

136

137

135

250

236

209

147

223

148

IN_18

IN_19

IN_20

IN_21

IN_22

IN_23

IN_24

IN_25

IN_26

IN_27

IN_28

IN_29

IN_30

IN_31

IN_32

WAKE

6)

Power supply electronics

Power supply

Power outputs

Switch-on signal

VSS_2

0 V/+5 V

13)

0 V/+5 V

13)

17)

B

B

B

A

18)

A

A

A

A

B

B

A

A

A

B

A

A

A

A

A

18)

A

B

A

A

B

A

A

A

A

A

A

A

A

B

A

A

B

VP_1

15)

Proportional outputs



Proportional output

Proportional output

Proportional output

Proportional output

Proportional output

Proportional output

OUT_1

5A

OUT_2

OUT_3

5A

OUT_4

153

2.5 A

177

2.5 A

154

2.5 A

178

2.5 A

OUT_5

5A

OUT_6

151

2.5 A

175

2.5 A

152

176

149

173

150

174

130

131

126

101

125

129

11)

Proportional solenoids

184

Pump forward

185

Pump reverse

186

EP permanent motor

EP temporary motor

2)

180

Pump neutral valve

Retarder valve

OUT_37

183

4.0 A

Parking brake valve feedback

OUT_38

184

3.0 A

Pump forward feedback

OUT_39

185

3.0 A

Pump reverse feedback

OUT_40

186

3.0 A

EP Motors feedback

OUT_41

179

4.0 A

Gearbox valves feedback/

MCR valves feedback

OUT_42

180

3.0 A

Pump neutral valve feedback

181

182

188

187

1)




Connection diagram RC12-10/30, part 2

Clutch pressure switch

Implement control axis 0 positive


Pump pressure MA

Pump pressure MB

Implement control axis 0 negative

Parking brake pressure switch


Sensor GND, connection, see page 13

U

Bat p

V p

V p

V p

V p

V p

V

Stop switch

Cruise control On

Cruise control Set

Velocity limitation switch

Driver on board switch

Power limitation switch

VSS_1 see page 13

VSS_2 see page 13

U

Ign see page 13

VSS_3 see page 13

1

2

1

2

1

2

228 INH

114 IN_42

115

IN_43

140 IN_44

155 IN_45

156 IN_46

172 IN_47

191 IN_48

192 IN_49

196

IN_50

249 IN_51

219

5)

VSS_1

232

16) 5)

VSS_2

255

5)

VSS_3

Constant voltage source 5 V/150 mA



119 IN_40

120 IN_41

164 IN_33

166 IN_34

231

IN_35

217 IN_36

226 IN_37

139

IN_38

141 IN_39

B

A

A

B

B

A

A

A

A

146

19)

Sensor ground 5 A

INH

12)

SW-INH

14)

6.5 V

C

C

C

C

C

C

C

C

C

C

3.3 V

Constant voltage

121 IN_62

Temperature gearbox oil switch

B

116 IN_63

Temperature motor/tank oil

9)

117 IN_64

B

B

118

IN_65

1st gear switch

VSS_1

145

138 IN_52

2nd gear switch

168

IN_53



Implement control axis 3 positive p

V p

V p

V


Swivel angle pump

(only prototype) p

V

WSI

GND

5 V

Sig 1

Sig 2

VSS_3

218 IN_54

229 IN_55

171 IN_56

VSS_1

227 IN_57

1

167 IN_58

2 169

IN_59

VSS_3

Pin 146

Sensor

GND

Motor V g min

switch

170 IN_60

B

Sensor ground 5 A

A

10)

B

10)

10)

B

A

A

A

A

A

A

165 IN_61

A

Switch outputs

VP_2

15)

Switch outputs

Switch outputs

Power outputs

11)

VP_1

15)

Switch outputs

OUT_19

128

3.5 A

5 A

OUT_20

103

3.5 A

OUT_21

107

2.2 A

5 A

OUT_22

106

2.2 A

OUT_27

243

3.5 A

Switch outputs

OUT_28

241

3.5 A

2)

OUT_23

190

2.2 A

5 A

OUT_24

OUT_25

5 A

OUT_26

189

2.2 A

2)

194

2.2 A

193

2.2 A

Relay

2)

Parking brake valve pin 183, page 13

Engine start allowed

(if necessary use external pull-down resistor)

Gearbox valve A

(2 + 1 Clutch valve)

(standstill/SoF gearbox)

(MCR 1; 50% / 100%)

Gearbox valve B


(MCR 2; 50% / 100%)

Gearbox valve C


(MCR 2; 0%)

Pin 179, page 13

Fault lamp

2)

Parking brake lamp

Battery T.30

Brake lamp

Pressure switch service brake

(external)

2)

Status lamp (gearbox)

242

256

244

257

VP_1

15)

OUT_33

105


OUT_34

104

OUT_35


OUT_36

127

102

OUT_47

4 ... 20 mA

221

195

CAN H1

CAN L1

215

216

4)

BODAS-service

250 kBaud

253

254

Engine J1939

250 kBaud

163

162

161

160

4) 16)

CCP

1000 kBaud

Connection diagram part 1: see page 15

1)




15

2

1−

Pin 146, page 2

Sensor GND

1

2

Pin 219, page 2

VSS_1

2)

270 Ω

1)

Option idle validation switch

U

Ign

3

4

1+

2−

1

2

Pin 146, page 2

Sensor GND

1)

2)

Active or passive potentiometer (1-4k)

Signal range must be 0.5 V to 4.5 V. Use additional resistances or built-in mechanical blocks to ensure the signal range

1)

2)

270 Ω / 2W

Pin 146, page 2

Sensor GND

1

2

Footer from page 13 and 14

1)

2)

Short, low-resistance connection from a case screw to the vehicle ground.

Separate ground connection to battery (Chassis possible).

3)

4)

5)

6)

7)

8)

9)

Separate fuses for switches and sensors necessary.

Sensor supply application specific.

CAN-bus: termination resistor 120 Ω and twisted pair wire necessary.

Outputs 5 V / 10 V can also be used as sensor supply alternatively.

Temporary wake up of the controller when a signal >8 V is applied for more than 1 sec.

Note max. current consumption with simultaneous actuation of proportional solenoid and switched outputs.

Separate ground connection for current source to battery, controller GND possible.

Can be used as switch inputs if externally switched to GND.

10)

For use as voltage inputs (0...10 V), the load can be stiched by the software in groups for these inputs.

Groups: inputs 1...2, inputs 3...6, inputs 7...10

11)

Outputs arranged in groups, each with 2 output stages.

Maximum permissible output current of a group: 5 A.

12)

Primary deactivation channel for proportional- and switch outputs: enabling with level >4.5 V, deactivation with level <1 V, cable break leads to deactivation.

13)

Input groups may be switched to pull down or pull up in software.

14)

Secondary deactivation channel for proportional- and switch aoutputs: enabling with level <0.8 V, deactivation with level >1.7 V, cable break leads to deactivation.

15)

Supply can be switched by the software.

16)

Is switched off when the watchdog triggers. Is switched off shortly for diagnosis purposes when a main switch is initially activated.

17)

If power is disconnected during operation no data can be saved to non-volatile memory and no after-run.

18)

A and B indicate different A/D converters which may be selected for redundancy reasons.

19)

Terminal 31 (supply ground) and sensor ground are bridged at a star point in the control-unit and connected to the housing.




5.2 CAN signals

▼ Up to four CAN channels are supported:

CAN 1

CAN 2

CAN 3

CAN 4

250 kBaud Communication with BODAS-service or

BODAS-design.

250 kBaud J1939 Standard. Communication with

diesel engine and other ECUs.

Reserved.

1000 kBaud Communication via CAN calibration

protocol (CCP).

Supporting development tools like

CANape, INCA or equivalent for advanced measuring options.

Caution: CCP must not be used for parameter setting or calibration.

Input and output signals for the driver and machine interface are sent on CAN channel 2 with a baud rate of

250 kBaud. The messages are built in accordance with the

J1939 standard.

For details, see the CAN database, which is part of the

BODAS-drive documents and tools container.

▼ Supported message interfaces

Signal is contained in a standard J1939 message.

CAN

SAE J1939

Standard

CAN

SAE J1939

Proprietary

Signal is contained in a proprietary J1939 message. All proprietary messages have a checksum and message counter for increased safety. All proprietary message identifiers can be commonly shifted via an offset parameter for free choice of identifier space.


5.3 Inputs

Range inputs



17

Supported electrical interfaces

Maximum signal voltage range

1)

Discrete

Open input

voltageV 2)

Remarks Supported

CAN messages

CAN Bus

Remarks

Drive pedal

Drive potentiometer

Inch pedal

3)

Brake pedal

Velocity limit

Tractive effort limit

Hand throttle

Engine speed, joystick request

Pump pressure

sensors M

A

and M

B

Pump swivel angle sensor

4)

0.5 to 4.5 V

2.7 V

0 V

▶ Signal range of first channel can be learned via trimming functionality of BODAS-service

▶ Idle validation switch must be connected to 5V

CAN

SAE J1939

Proprietary

Four channels per joystick:

▶ Positive and negative

deflection of x- and y-axis

▶ Signal range of each

channel can be learned via trimming functionality of BODAS-service

– –

Used for prototyping only.

No functionality assigned to this sensor

CAN

SAE J1939

Proprietary

Proprietary messages

include checksum and

message counter

–

Proprietary messages include checksum and message counter

▼ Supported electrical interfaces

V

This interface expects one analog voltage signal in the range from 0.5 V to 4.5 V.

The details of the signal characteristics including start and end point as well as the allowed tolerances can be configured via parameters.

x 5)

V

V

2

1

This interface expects two opposing voltage signals in the range from 0.5 V to 4.5 V.

The first signal is the leading signal and the second signal is used for plausibility check.


x 5)

V

2

V

1 x 5)

This interface expects two concurrent voltage signals in the range from 0.5 V to 4.5 V.

The first signal is the leading signal and the second signal is used as a plausibility check.


V

IVS

V

1

V

IVS

V

1

This interface expects one voltage signal in the range from 0.5 V to 4.5 V and one on/off idle validation switch V

IVS

signal. The voltage signal is the leading signal and the on/off signal is used as a plausibility check. The details of the signal characteristics including start and end point as well as the allowed tolerances can be configured via parameters.

x 5) x

5)

1)

Passive sensors such as potentiometers must be connected to a

5 V sensor supply (VSS_1 or VSS_3). Active sensors must be supplied as specified by sensor data sheet (VSS_1, VSS_2, VSS_3 or

U

Ign

).

2)

3)

4)

5)

Voltage measured in case of unconnected signal pin. Voltage results from internal circuitry of RC.

A combined brake / inch pedal must be connected as inch pedal

Such as implement pressure sensors or implement joystick x = angle α, line S or pressure p




Gearbox speed up to two speed sensors


DSM

Sensor supply

Discrete

1)

Signal channel of RC

HDD2 / DSA2

U

Ign

Remarks

Supported positions and

combinations of speed sensors are shown below

Supported

CAN messages

CAN Bus

Remarks

CAN

SAE J1939

Proprietary


Engine speed

– – –

CAN

SAE J1939

Standard

Standard EEC1 message


DSM

I

High

I

Low

t

HDD2 / DSA2

DSM Sensor:

This interface expects one frequency with coded error and direction information.

HDD2 2) / DSA2 Sensor:

This interface expects two frequencies with direction-dependent phase shift.

360° phase approx. 90° phase shift

Time t

▼ Supported positions and combinations of speed sensors

Gearboxes that can be shifted at a standstill require a speed sensor at the hydraulic motor (1), the gearbox input

(1*) or the gearbox output shaft (2*), respectively. For shift-on-fly a speed sensor at the gearbox output shaft (2*) is mandatory. The evaluation of two sensors is supported for additional diagnostics.

1*

1

2*

For summation gearboxes, two speed sensors are compulsory. Two combinations are supported for the sensor positions: Both speed sensors are placed either at the hydraulic motors (1, 2) or within the gearbox (1*, 2*).

2*

Permanently active motor

2

Temporarily active motor

(disengageable)

1

1*

For configurations with radial piston motors (up to four wheels) two speed sensors are recommended (sensor ( 2) is mandatory). The sensors must be placed at different motors.

1

2

1)

2)

Sensor dependent supply voltage

Only NPN type supported


Hydraulic motor oil

temperature

Gearbox oil temperature switch

Engine coolant

temperature

–


Discrete

Remarks

Supported sensor: TSF, TF-W

Switches may be normally opened



19

Supported

CAN messages

CAN Bus

Remarks

CAN

SAE J1939

Proprietary


–

CAN

SAE J1939

Standard

Standard ET1 message


Ω

This interface expects a temperature-dependent sensor resistance.

The available measurement range of the RC is supported by the software.




Switch inputs


Discrete

Closed

1)

switch voltage

Open

2)

switch voltage

Cruise control on

Remarks Supported

CAN messages

CAN Bus

Remarks

Cruise control set

Velocity limitation switch

Driver-on-board switch

Shift request shift up, shift down

Auto shift enable

0 V 6.5 V

2.7 V

5 V

Switches may be normally opened or closed

Parking brake request

Clutch pressure switch

Parking brake

pressure switch

Motor minimum displacement switch

Power limitation switch

Gear position switch

U

Ign

5 V

0 V

Switches must be normally opened. Switch closes if corresponding gear is engaged

FNR - Drive direction

select three channels:

neutral, forward and reverse

Drive mode select up to five channels

Emergency stop switch

Com

1

2 n

U

Ign

5 V

0 V and U

Bat

Supported electrical interfaces (see page 21)

Switches may be normally opened or closed

2.7 V

6.5 V and 0 V

Switches must be normally opened

Switch must have two

normally closed contacts

–

CAN

SAE J1939

Proprietary


–

1)

2)

External potential connected to RC by a closed switch.

Potential measured at RC pin at open switch. Voltage results from internal circuitry of RC.




21

▼ Supported electrical interfaces (from page 20)

This interface expects an on/off signal coming from a push button or switch with normally open contact.

This interface expects an on/off signal coming from a push button or switch with normally closed contact.

This interface expects two redundant on/off signals coming from a push button or switch with two normally open contacts.

This interface expects two redundant on/off signals coming from a push button or switch with two normally closed contacts.

This interface expects two redundant on/off signals coming from a push button or switch with one normally open and one normally closed contact.

Com

1

2 n

This interface expects exactly one of n signals in on-condition. Typical devices can be a steering column switch or any other selector switch with one common supply pin and n mechanical positions connecting the common pin with one of the n output pins.




5.4 Outputs

Proportional outputs

Pump solenoids


Default output logic

1)

Pump swivels to

V

g0

Discrete

Invertible

2) no

Hydraulic motor solenoids

Retarder solenoid

Desired engine speed

Motor swivels to

V

gmin yes

(V gmax yes

)

Remarks

Pump forward and reverse

solenoids are connected to two independent low-side switches

▶ All hydraulic motor solenoids are connected to one low-side switch.

▶ Output logic is

independently configurable for both motors

Retarder control can be proportional or digital

– – – –

Supported

CAN messages

CAN Bus

Remarks

CAN

SAE J1939

Proprietary

Proprietary

messages include checksum and

message counter

CAN

SAE J1939

Standard

CAN

SAE J1939

Proprietary

Standard TSC1

message

Proprietary

messages include checksum and

message counter


I

I

This high-side output expects a solenoid connected to ground potential. The proportional

output current is generated via PWM closed-loop control. The details of the solenoid characteristics including minimum and maximum resistance can be configured via parameters.

This high-side output expects a solenoid connected to a low-side switch. The low-side switch is an additional safety path for switching off the output in case of external short circuits. Up to four high-side switches can be connected to one low-side switch. The proportional output

current is generated via PWM closed-loop control. The details of the solenoid characteristics including minimum and maximum resistance can be configured via parameters.

1)

2)

For output that is shut off (no current), expected default machine behavior for a deactivated output

(no current driven by high-side output)

Indicates if output logic can be inverted by parameter




23

Switch outputs

Fault lamp

Parking brake lamp

Status lamp

(Gearbox)

Brake lamp via relay

Engine start allowed

Gearbox valves for standstill, shift-on-fly,

summation gearbox or MCR motor control

Parking brake valve

Pump neutral valve


Default output logic

1)

Discrete

Invertible

2)

Lamp is on

Lamp is on

Lamp is on

Lamp is on

Engine start is allowed

Valve is open

Parking brake is open

No short circuit between pump

X1, X2 yes yes yes yes no yes yes yes

Remarks

Lamp signals from lowest to highest priority: off, on, slow flash, fast flash

Lamp signals: off = brake disengaged, on = brake engaged, flashing = brake engagement is requested

Lamp signals: off = shifting not possible, on = shifting possible, flashing = shift up/down for fixed gear request currently not possible

–

If engine ECU input is active low, signal must be inverted

(e.g. with a normally open relay to GND)

▶ Up to three valve solenoids are connected to one low-side switch

▶ Output logic is independently configurable for all valves

Parking brake valve solenoid is connected to one low-side switch

Pump neutral valve solenoid is connected to one low-side switch

Supported

CAN messages

CAN Bus

Remarks

CAN

SAE J1939

Proprietary



V

V

V

This high-side output expects a solenoid connected to ground potential. The output voltage is switched to battery voltage or ground. The details of the solenoid characteristics including

minimum and maximum resistance can be configured via parameters.

This high-side output expects a solenoid connected to a low-side switch. The low-side switch is an additional safety path for switching off the output in case of external short circuits.

Up to four high-side switches can be connected to one low-side switch. The output voltage U is switched to battery voltage or ground. The details of the solenoid characteristics including minimum and maximum resistance can be configured via parameters.

This high-side output expects a resistance (e.g. a lamp) connected to ground potential. The

output voltage is switched to battery voltage or ground. The details of the resistance characteristics including minimum and maximum resistance can be configured via parameters.

1)

2)

For output in on state (U

Bat

), expected default machine behavior for an activated output (High-side output has battery potential).

Indicates if output logic can be inverted by parameter.




5.5 Power supplies

Battery power supply

▶ 12 V and 24 V batteries are supported.

▶ Different solenoids are to be used depending on the battery voltage. Thus different load resistances are expected for error detection.

The RC controller is using an after-run functionality.

Therefore battery power supply must not be disconnected within a time period of 2 seconds after switching of ignition.

Sensor supplies

U

Bat

▶ This potential is connected to battery voltage and is protected by a 5 A fuse.

▶ It is solely used for power supply of ECU electronics and the emergency stop switch.

U

Ign

▶ This potential is connected to the ignition switch and is protected by a 3 A fuse.

▶ It is used for sensors requiring battery voltage as power supply and for some switches.

▶ The sensors connected to U

Ign

don’t draw current when ignition is off.

VSS_1, VSS_3

▶ These potentials are connected to 5 V constant voltage sources supplied by the ECU.

▶ It is used for sensors requiring a 5 V power supply, for potentiometers and for some switches.

VSS_2

▶ This potential is connected to a 10 V constant voltage source supplied by the ECU.

▶ It is not used in the BODAS-drive DRC wiring harness.



Functional safety in accordance with EN ISO 13849 and ISO 25119

25

6 Functional safety in accordance with EN ISO 13849 and ISO 25119

6.1 Approach

BODAS-drive uses a subsystem approach as stated in the figure below.

The following approach shows how the machine manufacturer can reach the required performance level for a specific application applying BODAS-drive.

Subsystem

Driver interface

+ machine sensors

Drivetrain system

Subsystem

BODAS controller RC

+

BODAS-drive DRC

The machine manufacturer can use the BODAS controller

RC + BODAS-drive DRC subsystem within the machine safety design to realize safety functions for the drivetrain system. The described characteristics within this data sheet refer to the BODAS controller RC + BODAS-drive DRC subsystem.

Ready-to-use safety functions developed according to the standards EN ISO 13849 and ISO 25119 are part of the software. If the performance level for the BODAS-drive subsystem is sufficient to reach the required overall performance level, BODAS-drive can be used based on the customer-specific risk assessment. In any case, the requirements of the relevant safety standard must be fulfilled at the drivetrain and machine level.

Subsystem

Hydraulics

+

Mechanics

6.2 Concept

The software of the BODAS controller RC + BODAS-drive

DRC subsystem utilizes an inherent safety concept. This means that all noted safety functions are realized not by dedicated monitoring software, but by a safe implementation of the safety relevant software program parts. The

BODAS-drive software has been completely developed according to PL d and SRL 1. The software comes with 8 predefined safety functions, but is not limited to these. For additional safety functions, contact your Bosch Rexroth sales partner.

1 Risk assessment

▶ Performance of risk assessment

▶ Identification of the safety functions

▶ Determination of the required performance level (PLr)

2 Safety concept and category selection →

Category 2 is pre-defined for BODAS controller RC +

BODAS-drive DRC subsystem

▶ Comparison of risk assessment results with safety functions offered within BODAS-drive

▶ If the safety requirements of the application cannot be fulfilled with the existing safety functions of BODASdrive, the product must not be used. In this case, consult your Bosch Rexroth contact regarding a customized solution. Otherwise go on with the next step.

▶ Developing a safety concept for the complete machine and drivetrain

– Applying BODAS-drive inherent safety approach

– Creating block diagrams

– Calculation of the overall performance level. The

SISTEMA tool from IFA may be used. A calculation example is provided. Once the safety function groups and the characteristics of the sensors and actuators have been provided, it can directly calculate the probability of failure per hour and the performance level achieved.

3 Integration and parameterization of BODAS-drive in the machine

▶ Integrate BODAS-drive in the machine environment interfacing the wiring harness and devices which are selected according to the safety requirements.

▶ Set parameters with BODAS-service according to the application-specific requirements.

This inherent approach is combined with a safe diagnosis system within the BODAS-drive software, fulfilling the requirements of category 2: Detection of and appropriate reaction to hardware faults.

As BODAS-drive represents a safety element out of context

(SEooC), the machine manufacturer must verify whether it is the right product for the specific application. In any case, the machine manufacturer is responsible to fulfill the overall safety requirements at the machine level.

4 Validation

▶ Creation of an appropriate application-specific approval test specification.

The BODAS-drive approval test specification is part of the documents and tools container and can be used as a starting point. An application-specific adaptation is required in any case.

▶ Performance of approval tests specific to application and project as well as documentation of the results.




6.3 Safety functions

All Safety functions of the BODAS-drive subsystem have been developed according to PL d (DIN EN ISO 13849) and

AgPL c (ISO 25119). The software has been developed to fulfil the requirements of PL d (DIN EN ISO 13849) and

SRL 1 (ISO 25119). The ECU hardware fulfils the requirements of category 2 according DIN EN ISO 13849 and

ISO 25119.

Relationship between safety functions and input/output functions

The following tables show the dependencies between safety functions and configured components.

The following table shows, which input and output components are related to each declared safety function.

For example, to know which components have a dependency for e.g. the safety function “Safe Reversing”, the “x” marks in the line of “Safe Reversing” show which components have to be regarded. In this case, these are

▶ Drive pedal

▶ Drive potentiometer

▶ Drive direction select

▶ Speed sensor 2

▶ Pump actuation


Inputs

Machine interface Driver

Outputs


Safe standstill

Safe parking brake x x x x

Safe direction

Safe acceleration and deceleration Limit

Safe reversing x x x x x x x

Safe brake light

Safe limited speed

Safe deceleration

Safe operator detection x x x x x x x x x x x x x x x x = mandatory for safety function (if sensor is used for configured function) x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

1)

2)

With summation gearbox (e.g. 2+1)

With standstill gearbox (up to 3 gears)


Relationship between safety functions and vehicle functions

The following tables show the dependencies between safety functions and configured functionality.

The following table shows, which functionality is related to each declared safety function. For example, to know which functionality has a dependency for e.g. the safety function

“Safe Reversing”, the “x” marks in the line of “Safe Reversing” show which functionality is affected. In this case, these are

▶ Pump control

▶ Reversing Function



27

Safe standstill

Safe parking brake

Safe direction

Safe acceleration and deceleration limit

Safe reversing

Safe brake light x x x

Safe limited speed

Safe deceleration

Safe operator detection x x = mandatory for safety function (if component is configured) x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x




SF1: Safe standstill

This safety function ensures no unwanted self-propelled movement of the machine caused by an unwanted torque of the hydrostatic transmission.

PFH value for the BODAS controller RC + BODAS-drive DRC subsystem for this function is about 2.6 · 10 –7 . This value depends on the connected sensors and the type of connection (such as analog or CAN…).

Driver interface + machine sensors

BODAS controller RC

+ BODAS-drive DRC

Hydraulics +

Mechanics

Drive pedal

Pump

SF4: Safe acceleration/deceleration limit

This safety function ensures that the vehicle accelerates or decelerates as the driver expects.




Hydraulics +

Mechanics

Driver-on-board switch

Drive pedal

Parking brake request

Valve parking brake

F-N-R Drive direction


Inch pedal

Brake pedal


Pump

Hydromotor EP

SF2: Safe parking brake

This safety function prevents the parking brake from releasing unintentionally when the vehicle is at a standstill.

Speed motor 1

Valve parking brake




Hydraulics +

Mechanics

Speed motor 2



Valve parking brake


SF5: Safe reversing

This safety function ensures the execution of a reversing action when (and only when) the driver demands it by switching the F-N-R switch.




Hydraulics +

Mechanics

SF3: Safe direction

This safety function prevents the vehicle from propelling into the wrong direction. It ensures that the hydrostatic transmission issues torque in the direction the driver demands.




Hydraulics +

Mechanics

Drive pedal

Pump


PFH value for the BODAS controller RC + BODAS-drive DRC subsystem for this function is about 2.6 · 10

–7

. This value depends on the connected sensors and the type of connection (such as analog or CAN…).


Pump




29

SF6: Safe brake light actuation

This safety function controls the brake lights depending on a calculated deceleration value.




Hydraulics +

Mechanics

SF8: Safe deceleration

This safety function ensures that the hydrostatic transmission issues a braking torque when the driver demands it. The available braking torque is limited to the diesel drag torque. The diesel overspeed protection function has higher priority than this safety function.

Speed motor 1

Brake lights relay

Speed motor 2

PFH value for the BODAS controller RC + BODAS-drive DRC subsystem for this function is about 2.3 · 10

–7

. This value depends on the connected sensors and the type of connection (such as analog or CAN…).


Drive pedal

Inch pedal



Hydraulics +

Mechanics

Pump

Brake pedal

SF7: Safe speed limitation

This safety function safely limits the vehicle speed. The available deceleration is limited by the available diesel drag torque. The engine overspeed protection has higher priority than this safety function.




Hydraulics +

Mechanics


Valve parking brake



Speed motor 1

Pump

Speed motor 2

Hydromotor EP temp

SF9: Safe operator detection

This safety function ensures that the hydrostatic transmission stops propelling the vehicle as long as the operator is not present at the operator’s position.




Hydraulics +

Mechanics

CAN

Engine speed

Hydromotor EP perm


Driver-on-board switch

Pump





6.4 Example of using a BODAS-drive safety function

This chapter uses an example based on SF1 Safe Standstill to show how to use the standard BODAS-drive safety functions depending on the machine configuration.

First step: Develop a block diagram

Develop the block diagram based on the machine configuration and desired functionality. The usable blocks of the

BODAS controller RC are defined within the safety-relevant project instructions, Rexroth datasheet 95451-01-B of the choosen ECU. The appropriate blocks of the subsystem of sensors and hydraulics have to be choosen according to the machine configuration.

The example shows a block diagram for the safety function

SF1, “Safe Standstill”. It makes use of a 2-channel drive pedal, a 2-channel parking brake switch, a driver-on-board switch and a 3-position F-N-R switch on the sensor side and an electrically controlled pump and parking brake valve on the hydraulic side.

The block diagram shows the connection of all blocks relevant for this safety function. It also shows the choosen category, here category 2 with a function channel and a test channel.


Drive pedal

Driveron-boardswitch



BODAS controller RC + BODAS-drive DRC

Analog input

Processor/

RAM

PWM output

HS

Circuit board/ supply

Digital input

CAN module

Sensor supply

Alternative: S1, S3, S5, S6 via CAN

HW-

Monitoring

Out

Enable/

Inhibit

Digital input

PWM output

LS

Analog input

Hydraulics + Mechanics

Pump

Valve parking brake


Second step: Calculate metrics

The metrics of MTTF d

and DC value are calculated in the second step. Bosch Rexroth recommends using the

SISTEMA tool for that purpose.

✔

SF

Safe standstill

✔

SB

ECU

✔

CH

✔

Channel 1

✔

BL

K2 – Analog input

✔

BL

K2 – Analog input

BL

K2 – Analog input

✔

BL

K3 – Digital input

✔

BL


✔

BL

K5 – Processor and memory

✔

BL

K7 – CAN bus

✔

BL

K11 – Sensor supply

✔

BL

K6 – Power supply unit and circuit board

✔

BL

K8 – PWM output highside

✔

✔

BL


✔

BL


TE

Test channel

✔

BL

K2 – Analog input

✔

BL

K2 – Analog input

✔

BL

K2 – Analog input

✔

BL


✔

BL


✔

BL

K4 – Monitoring

✔

BL

K13 – INH (inhibit, pin 228)

✔

BL


✔

BL

K9 – PWM output lowside

✔

BL


✔

BL


✔

BL




31

Result for the BODAS controller RC + BODAS-drive DRC subsystem is:

SF

Safe standstill

PLr

PL

PFH [1/h] d d

6.61E-7

SB

ECU

PL

PFH [1/h]

Cat.

MTTF d

[a]

DCavg[%]

CCF d

3.49E-7

2

100 [high]

77.94 [low]

75 [fulfil]

According to the BODAS controller RC + BODAS-drive DRC subsystem, the calculation for the full system has to be done based on the respective machine. The database of the used values can be found within the safety-relevant project planning instruction for BODAS controllers RC, Rexroth datasheet 95451-01-B. Since the sensor and system structures vary, a concrete calculation has to be done within each project. Also, the machine-specific temperature profile has to be taken into account when performing the MTTF d value calculation.



Project engineering and ordering information

7 Project engineering and ordering information

The way from machine prototyping to serial production

▶ The outputs of the BODAS controller RC + BODAS-drive

DRC are deactivated in the initial delivery status.

▶ The scope of supply (as described above) must be applied and each controller has to be parameterized.

Access to the parameters is password-protected. The password is part of the documents and tools container.

▶ The machine manufacturer must verify and validate

BODAS-drive in regard to the machine-specific requirements.

Important:

▶ The details in chapter 6, Functional safety, must be taken into account.

▶ Please take into account the Rexroth brochure

„10 steps to performance level“.

▶ A customer-specific parameter file has to be transferred to each controller for serial production.

For a customer-specific software solution please contact your Bosch Rexroth sales partner.

Required tools

▶ BODAS-service V3.4.1 or higher; for the latest version see www.boschrexroth.com/mobile-electronics

▶ Microsoft Excel or equivalent for handling the approval test specification

Recommended tools

▶ Sistema, software tool for the application of the standard EN ISO 13849-1

▶ Vector CANalyzer Pro version 7.6 or higher – required for full functionality including virtual testbox and plant model.



Project engineering and ordering information

33

7.1 Ordering code

01

ASrun /

02

DRC

03

A

04

41

Type

01 Application software ready to run on RC controller

Application

02 Hydrostatic drivetrains for wheeled mobile machines

Variant

03 Hydraulic pump A4VG.ET or EP, engine with SAE J1939 CAN interface, hydraulic motor with constant displacement or

A6VM.EP, fixed gear or gearbox shiftable during standstill or shift-on-fly gearbox or summation gearbox interfacing two hydraulic motors or hydraulic transmission using radial pistion motors type MCR.

Release

04 Release number of the software

ASrun

DRC

A

41

The software BODAS-drive DRCA41 will be delivered already flashed on a BODAS controller RC12-10/30

When placing an order, the hardware and software ordering codes are to be linked by a “+“.

In this case the complete ordering code is as follows: RC12-10/30 + ASrun/DRCA41

Documents and tools container

To assist in handling the product properly, the documents and tools container has associated files and documents available, including the following contents:

▶ Operating instructions (Application guideline, detailed functional description and parameter description)

▶ User password to access the parameters via BODAS-service

▶ Test specification example file for approval test

▶ Sistema calculations, example file

▶ Proprietary SAE J1939 messages including code for calculation of CRC checksum and message counter for integration of other control units within the CAN network.

▶ Measurement, calibration and testing-tool support

▶ CAN database of proprietary SAE J1939 messages

▶ CANalyzer configuration including virtual testbox and plant model of the drivetrain (optional)

The operating instructions as well as the valid standards and separate documentation (chapter 8) must be considered before start-up of the software.

The documents and tools container is provided upon request via [email protected]

Please use the following subject for your e-mail request: “Container request: ASrun/DRCA41“

Please provide additionally the following information:

▶ Company name

▶ Contact person

▶ E-mail address

▶ Purchase order number



Valid standards and separate documentation

8 Valid standards and separate documentation

Document

SAE J1939-21 December 2010

SAE J1939-71 May 2012

Standard DIN ISO 13849-1 2006-11

Standard DIN ISO 13849-2 2012-10

Standard ISO 25119 2010-06 Parts 1-4

95204

95451-01-B

08511 10

▼ Compatible Rexroth products

Components

Axial piston variable pump A4VG…EP and ET/40

Axial piston variable pump A4VG…EP/32

Axial piston variable motor A6VM…EP/71

Radial piston motor for wheel drives MCR-F

BODAS Pressure sensor PR3

BODAS Speed sensor DSM

BODAS Temperature sensor fluid TSF

BODAS Speed sensor HDD

BODAS Angle sensor WS1

BODAS Controller RC series 30

BODAS-service

BODAS measuring adapter MA6

Data Link Layer

Vehicle Application Layer

Safety of machinery – Safety-related parts of control systems

Part 1: General principles for design

Part 2: Validation

Tractors and machinery for agriculture and forestry – Safety-related parts of control systems

BODAS Controller RC series 30

RC12-10, RC20-10, RC28-14

Controller RC12-10, RC20-10, RC28-14

Safety-relevant project planning instruction

10 Steps to Performance Level

Data sheet

92004

92003

91610

15198

95155

95132

95180

95135

95140

95204

95086

95090

Relevant type code

EP – Electric control, proportional

ET – Electric control, direct-controlled



PR3 600MD36/10, PR3 600GS05/10

DSM1-10

HDD2L16N

WS1T90/10

RC12-10/30


9 Abbreviations

ISO

IVS

LS

MCR

MTTF d

PFH

PL

PLr

PWM

RC

DRC

ECU

EN

EP

ET

FNR

HA

HS

IFA

Abbreviation Meaning

AgPL

BODAS

CAN

Agriculture Performance Level

Bosch Rexroth Design and Application System

Controller Area Network

CCF

CCP

DA

DC

DHC

DIN

Common Cause Failure

CAN Calibration Protocol

Automatic control speed-related

Diagnostic Coverage

Diesel Hydraulic Control

Deutsches Institut für Normung

Drive Control

Electronic control unit

European Norm

Proportional control electric

Electric control, direct-controlled

Forward/Neutral/Reverse

Automatic control high-pressure related

High-Side

Institute for work protection of the German

statutory accident insurance

International Organization for Standardization

SAE

SEooC

SF

SISTEMA

SRL

Idle validation switch

Low-Side

Radial piston motors

Mean Time To dangerous Failure

Probability of dangerous failure per hour

Performance Level

Required Performance Level

Pulse-width modulation

Rexroth Controller

Society of Automotive Engineers

Safety element out of context

Safety Function

Safety integrity software tool for the evaluation of machine applications, produced by IFA

Software Requirement Level


Abbreviations

35



Safety Instructions

10 Safety Instructions

▶ BODAS-drive DRC represents a safety element out of context (SEooC). The machine manufacturer must verify whether it is the right product for the specific application.

▶ The machine manufacturer must perform a risk assessment.

▶ The required safety functions and performance levels must be fulfilled with the product in order to use

BODAS-drive DRC in a specific application.

▶ The machine manufacturer bears responsibility for applying the valid safety standards at the machine level.

▶ The machine manufacturer is responsible for fulfilling all safety requirements at the drivetrain and machine level.

▶ The machine manufacturer is responsible for validating the machine-specific configuration of BODAS-drive DRC.

▶ Configurations of BODAS-drive DRC used for serial production must be validated.

▶ The proposed circuits do not imply any technical liability for the system on the part of Bosch Rexroth.

▶ Incorrect connections could cause unexpected signals at the outputs of the RC.

▶ Incorrect programming or parameter settings may create potential hazards while the machine is in operation.

▶ It is the responsibility of the machine manufacturer to identify hazards of this type in a hazard analysis and to bring them to the attention of the end user. Bosch

Rexroth assumes no liability for dangers of this type.

▶ The application software must be installed and removed only by Bosch Rexroth or an authorized partner to preserve the warranty.

▶ It must be ensured that the vehicle is equipped with adequately dimensioned service and parking brakes.

▶ Make sure that the software configuration does not lead to safety-critical malfunctions of the complete system in the event of failure or malfunction. This type of system behavior may put life in danger and/or cause great damage to property.

▶ System developments, installations and commissioning of electronic systems for controlling hydraulic drives must only be carried out by trained and experienced specialists who are sufficiently familiar with both the components used and the complete system.

▶ The machine may pose unforeseen hazards while commissioning and maintenance are carried out. Before commissioning the system, you must therefore ensure that the vehicle and the hydraulic system are in a safe condition.

▶ Make sure that nobody is in the machine’s danger zone.

▶ No defective or incorrectly functioning components may be used. If the components should fail or demonstrate faulty operation, repairs must be performed immediately.

▶ The technical specifications and safety instructions of all involved components must be considered.

▶ The machine manufacturer must follow the valid standards and separate documentation (see chapter 8) when using the product.

Intended use

▶ The control unit is designed for use in mobile working machines provided no limitations / restrictions are made to certain application areas in this data sheet.

▶ Operation of the control unit must generally occur within the operating ranges specified and released in this data sheet, particularly with regard to voltage, current, temperature, vibration, shock and other described environmental influences.

▶ Use outside of the specified and released boundary conditions may result in hazard to persons and/or cause damage to components which could result in subsequential damage to the mobile working machine.

Improper use

▶ Any use of the control unit other than as described under “Intended use” is considered to be improper.

▶ Use in explosive areas is not permissible.

▶ Damage resulting from improper use and/or from unauthorized interference in the component not described in this data sheet render all warranty and liability claims void with respect to the manufacturer.

Bosch Rexroth AG

Mobile Applications

Glockeraustraße 4

89275 Elchingen, Germany

Tel. +49 (0)9352 40 50 60

[email protected]

www.boschrexroth.com/mobile-electronics

© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.

Application software BODAS-drive DRC

Application software

BODAS-drive DRC

1 Introduction 2 Typical applications and variants

3 System description

4 Functional description

5 Electrical interfaces

6 Functional safety in accordance with EN ISO 13849 and ISO 25119

7 Project engineering and ordering information

8 Valid standards and separate documentation

9 Abbreviations

10 Safety Instructions

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