Description
1. Overview
The REXROTH VT-HNC100-1-22/W-08-C-0 is a high-performance single-axis digital hydraulic closed-loop controller of Bosch Rexroth HNC100 series. Designed for precision hydraulic servo and proportional systems, it integrates position, speed and force/pressure closed-loop control algorithms. It drives hydraulic servo valves and proportional valves to realize high-precision positioning, constant-speed operation and constant-force pressing, widely used in metallurgical presses, injection molding machines, forging equipment and CNC machine tool hydraulic systems.
Adopting full digital architecture, the controller eliminates parameter drift caused by temperature and component aging compared with traditional analog control modules. It features high control accuracy, strong anti-interference capability, fixed parameter storage and convenient debugging. It solves common hydraulic problems such as crawling, overshooting and positioning deviation, serving as a core control unit for new equipment matching and old hydraulic system upgrading.
2. Technical Features
2.1 Multi-Mode High-Precision Closed-Loop Control
Supports seamless switching of position, speed and pressure/force closed-loop modes. Equipped with Rexroth adaptive hydraulic PID algorithm, it automatically adapts to cylinder inertia, load disturbance and oil temperature changes, effectively suppressing hydraulic impact, overshoot and low-speed crawling. It achieves micron-level positioning accuracy and stable dynamic response for precision industrial processes.
2.2 Full Digital Design Without Parameter Drift
All control parameters, gains, limits and ramp times are digitally stored and solidified. No potentiometer adjustment is required, avoiding parameter offset caused by device aging and temperature variation. Consistent control performance is maintained during long-term continuous operation without frequent calibration.
2.3 Built-In Professional Hydraulic Process Logic
Preloaded with dedicated hydraulic control functions including soft start, acceleration/deceleration ramp limit, stroke limit protection, overload pressure limitation, zero dead zone compensation and valve zero self-calibration. It independently completes full hydraulic process sequences such as pressing, pressure holding, pressure relief and return without complex PLC programming.
2.4 Rich IO Configuration for Independent Interlock Control
Integrates programmable digital and analog interfaces to connect displacement rulers, pressure sensors and speed feedback devices. It outputs equipment status and fault signals to realize start-stop interlock, safety limit and fault shutdown functions, completing full closed-loop control of single hydraulic axis independently.
2.5 Standard Industrial Bus Networking
Supports mainstream industrial communication protocols for real-time data interaction with PLC and HMI. It realizes remote parameter reading and writing, condition monitoring, fault tracing and formula calling, adapting to intelligent automated production line networking requirements.
2.6 Industrial Rugged Design for Harsh Environments
Metal reinforced housing and EMC compliance ensure strong vibration resistance and anti-interference performance. The pluggable terminal design prevents loose connection and misplugging, suitable for long-term 24/7 operation in dusty, oily and vibrating hydraulic workshop environments.
2.7 High Compatibility & Convenient Debugging
Matched with Rexroth servo/proportional valves and compatible with mainstream hydraulic valve brands. Professional supporting software supports online monitoring, curve recording and gain fine-tuning, enabling direct replacement of old analog controllers with low renovation cost.
3. Detailed Specifications
3.1 Basic Hardware Parameters
- Model: VT-HNC100-1-22/W-08-C-0
- Manufacturer: Bosch Rexroth
- Series: HNC100 Digital Hydraulic Axis Control Series
- Type: Single-Axis Digital Hydraulic Servo/Proportional Closed-Loop Controller
- Controlled Axes: 1 Axis
- Mounting: 35mm DIN Rail / Panel Screw Fixing
- Wiring: Front Pluggable Terminals (0.75~2.5mm² Wire)
- Human Interface: Status Indicators & Operation Keys
- Weight: Approx. 1.0kg
- Structure: Industrial Metal Housing, Dust-proof & Vibration-resistant
3.2 Electrical Parameters
- Operating Voltage: 18~36VDC (Standard 24VDC)
- Rated Current: 10A
- Ripple Voltage: ≤1.5Vpp
- Protection: Over-Voltage, Under-Voltage, Short-Circuit, Reverse Polarity & Surge Protection
- Recommended Fuse: 1.25A Slow Fuse
3.3 IO & Sampling Parameters
- Digital IO: 8-channel Programmable Input/Output for Interlock & Alarm
- Analog Input: Differential Voltage Input (±10V) for Sensor Acquisition
- Feedback Adaptation: Displacement, Pressure and Speed Sensors
- Control Output: High-Linearity Servo/Proportional Valve Drive Output
- Memory: 1MB Flash, 8KB EEPROM, 256KB RAM
3.4 Control Functions
- Control Modes: Position / Speed / Pressure-Force Closed-Loop
- Algorithm: Adaptive PID, Zero Offset Compensation, Load Disturbance Compensation
- Process Functions: Soft Start, Ramp Acceleration/Deceleration, Pressure Holding & Relief
- Diagnosis: Sensor Break Detection, Valve Fault Detection, Over-Travel & Overload Alarm
3.5 Environmental Parameters
- Operating Temperature: 0℃ ~ +60℃
- Storage Temperature: -20℃ ~ +70℃
- Operating Humidity: 10%～90%RH (Non-Condensing)
- Vibration Resistance: Industrial Grade Anti-Vibration
- EMC Performance: High Immunity to Industrial Electromagnetic Interference
4. Operating Principle
After power-on and self-inspection, the VT-HNC100 controller initializes hardware, parameters and communication. It synchronously collects real-time feedback signals of hydraulic axis displacement, speed and system pressure, and calculates output commands by comparing actual values with target values.
The controller switches control modes automatically according to process requirements: precise position correction for fixed-point docking, constant-speed adjustment for stable feeding, and constant-pressure control for pressure holding. Built-in ramp and buffer algorithms eliminate hydraulic impact during start-stop and commutation.
The system monitors sensor status, valve operation and system pressure in real time. It triggers interlock shutdown and alarm protection upon faults such as sensor disconnection, valve failure, over-travel and overload, and records fault data for traceability, realizing fully automatic closed-loop hydraulic process control.
5. Application Scenarios
1. Precision hydraulic forming equipment: stamping presses, forging machines, bending machines and injection molding machines.
2. CNC machine tool hydraulic feed and servo control systems.
3. Automatic hydraulic tooling and positioning stations for production lines.
4. Digital renovation of legacy analog hydraulic control systems.
5. Heavy-duty hydraulic executive equipment in metallurgical and industrial testing fields.
