Finding the right mobile controller for your machinery doesn’t have to be overwhelming. At its core, it’s about understanding your unique needs and customizing a solution that ensures top performance and functional safety for your equipment.
If integrating mobile controllers sounds complicated, don’t worry—we’ve got you covered. At Airline, we break it down step by step, guiding you through the process to achieve a seamless and successful outcome.
In this article, we’ll explore what mobile controllers are, compare options from HYDAC and Bosch Rexroth, and highlight how these solutions can take your mobile machinery to the next level. Let’s dive in!
In this Post
What Are Mobile Controllers and Why Are They Important? | HYDAC vs. Bosch: Similarities and Differences | Application Examples: Real-World Success Stories | Choosing the Right Mobile Controller for Your Needs | Working with Experts to Get It Right | Additional Resources
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Mobile controllers are the "brains" of heavy machinery, enabling advanced functionality and safety. They coordinate and control subsystems such as hydraulic valves, joystick inputs, and safety mechanisms to ensure smooth, reliable operation.
Functional Safety: Features like redundant inputs, current watchdogs, and emergency stops help prevent accidents and meet safety standards.
Optimized Performance: Mobile controllers ensure machinery runs efficiently, reducing downtime and costly maintenance.
Whether you’re operating cranes, bulldozers, Autonomous Guided Vehicles (AGVs), or other mobile equipment, mobile controllers are critical for achieving precision and reliability.
HYDAC and Bosch Rexroth both provide reliable mobile controllers for a range of applications, but each has strengths that cater to specific needs. When selecting a mobile controller, understanding these different strengths is crucial. Let’s take a closer look at HYDAC and Bosch Rexroth:
Feature | HYDAC | Bosch Rexroth |
---|---|---|
Core Focus | Thermal management, AGVs, and decentralized control for subsystems | Advanced software packages for functional safety and system integration |
Ideal Applications | Autonomous Guided Vehicles, modular hydraulic systems, and mobile equipment | Vehicle drives, pumps, motors, and heavy equipment control |
Key Strengths | Flexibility, modularity, precise control | Scalable, pre-certified solutions with integrated hardware and software platforms |
Unique Offerings | Independent subsystem controllers | BODAS hardware/software ecosystem with functional safety blocks and seamless integration |
HYDAC Mobile Controllers are mainly known for their focus on thermal management in demanding applications such as fuel cells and battery charging technology. They are often used as small subsystem controllers, capable of handling temperature control independently and reporting back to a higher-level controller. These controllers also excel in AGVs. This decentralized approach is similar to how automotive subsystems operate — allowing greater flexibility and modularity in mobile equipment and AGVs.
On the other hand, Bosch Rexroth Mobile Controllers are known for their advanced software packages, pre-certified to meet functional safety requirements. Now, they also have BODAS Hardware and Software available, Bosch Rexroth's advanced, open, and scalable mobile electronics platform, designed to meet the complex needs of mobile machinery. The inclusion of ASRun function blocks designed with functional safety at their core further highlights Bosch Rexroth’s focus on reliability and precision.
BODAS Hardware consists of a wide range of components, including control units, connectivity devices, sensors, and human-machine interfaces (HMIs) like joysticks, displays, and pedals. The individual BODAS hardware components are freely programmable and fully compatible with the BODAS Connect system, allowing for easy integration and customization.
This makes Bosch a great choice for those looking for prepackaged solutions to streamline machinery control integration.
Want to learn more? Check out the BODAS-SERVICE 3.X FULL software package offered by Bosch Rexroth for mobile hydraulic systems as part of the BODAS. Or download this whitepaper, "BODAS – Intelligent Electronics for Mobile Hydraulics."
Both controllers do an excellent job at machine control, offering extensive functional safety capabilities. Each company also has an extensive array of HMI screens, sensors, and cameras to complement its control systems. However, Bosch Rexroth’s functional blocks are equipped with advanced functional safety, while HYDAC excels in thermal management and AGV applications.
💡 The key to success with either system is to create a functional specification, including failure mode analysis, at the beginning of any machine control project.
Forklifts and Cranes: HYDAC controllers have been successfully used to manage hydraulic systems for cranes, leveraging their valving capabilities to handle control-intensive applications. Meanwhile, Bosch controllers have excelled in vehicle drives and heavy equipment applications, providing precise control for pumps and motors.
Flail Mowers: One interesting use case is the deployment of HYDAC controllers in flail mowers, commonly used along highways. These machines feature a rotating arm fitted with cutting chains to mow grass efficiently, even in uneven terrain. The HYDAC controller ensures the correct positioning and smooth operation of the arm, while also allowing the system to react to obstacles without causing damage.
Thermal Management for Batteries: Another major area for HYDAC is thermal management in electric and hybrid vehicles. The controller manages temperatures for fuel cells or battery packs, a critical function for maintaining system efficiency and extending battery life. This capability highlights HYDAC’s strength in thermal control for emerging technologies.
AGVs and Mobile Equipment: HYDAC Provides reliable subsystem control for AGVs, ensuring precision and efficiency in autonomous operations. HYDAC's controllers enable seamless navigation, obstacle detection, and path planning for AGVs, which are crucial for warehouse automation and industrial logistics. By integrating precise control with modular subsystems, HYDAC ensures that mobile equipment operates efficiently and adapts to dynamic environments, enhancing productivity and safety.
When integrating mobile controllers into machinery, the journey often involves more than just choosing a product. It requires a detailed understanding of your equipment, the specific functions it needs, and the safety standards it must meet. At Airline, our team of experts works closely with engineering managers, controls managers, and system architects to develop a solution that aligns with your needs. Our structured approach looks like this:
1. Consultation: Understanding your equipment, functions, and safety requirements. This often involves rigorous questioning to understand every aspect of your machine — from routine operations to potential failure modes. This ensures that the final solution not only meets functional requirements but also upholds the highest safety standards.
2. Custom Solutions: Tailoring controllers to your specific application.
3. Support: Providing ongoing technical support to ensure long-term success.
Partnering with us means leveraging decades of experience to achieve optimal performance and safety for your machinery.
If you're looking to integrate or upgrade your equipment, reach out to us to schedule a consultation with our mobile hydraulics experts and your local sales representative to discuss which mobile controller solution fits your needs.