Description

Rexroth SYHNC100-NIB-2X/W-24-P-D-E23-A012

1. Basic Information

REXROTH SYHNC100-NIB-2X/W-24-P-D-E23-A012 is a full-digital hydraulic axis control drive module and an industrial dedicated servo closed-loop control unit. It serves as the core intelligent drive component applicable to high-precision hydraulic servo systems, proportional valve control systems and multi-axis synchronous motion control. Adopting 2X enhanced configuration, equipped with E23 bus architecture and A012 customized program version, it is designed for high-end precision hydraulic molding, heavy-duty forging pressing and high-precision testing equipment. It realizes full closed-loop dynamic regulation of position, pressure, speed and flow of hydraulic actuators, and is widely applied to CNC hydraulic machine tools, injection and die-casting equipment, heavy-duty forging machinery, automatic hydraulic production lines and precision testing devices.

The module adopts full-digital DSP high-speed computing architecture, highly integrating signal acquisition and conditioning, multi-mode PID closed-loop calculation, dynamic load compensation, power drive amplification, industrial bus communication and comprehensive fault diagnosis and protection functions. It can directly drive servo proportional valves, high-frequency hydraulic servo cylinders and hydraulic servo motors, thoroughly eliminating defects of traditional analog hydraulic control such as temperature drift, signal lag, zero offset and poor anti-interference performance. Compared with standard models, it is fitted with upgraded 2X enhanced control algorithm, matched with 24VDC standard industrial power supply, E23 advanced bus configuration and A012 dedicated control program. It features faster dynamic response, higher control resolution and stronger load adaptability, perfectly satisfying stringent working conditions of high-frequency reciprocation, heavy load fluctuation and high-precision pressure stabilization and positioning. It greatly improves processing consistency, operational stability and technological accuracy of equipment.

Featuring industrial reinforced modular design, the product has compact structure and excellent vibration and interference resistance. It supports multi-protocol industrial bus communication and can seamlessly connect with PLCs, industrial controllers and upper configuration control systems of all brands. It enables programmable parameters, real-time online debugging, parameter auto-tuning and adaptive zero calibration as well as intelligent self-diagnosis. Suitable for 24-hour continuous operation and complex industrial environments with heavy dust, severe vibration and strong electromagnetic interference, it acts as a core high-precision drive and control unit for high-end hydraulic automatic control systems.

2. Technical Specifications

2.1 Core Electrical & Control Specifications

Power Supply: Standard 24VDC industrial control voltage, stable operating voltage ranges from 18 to 30VDC to adapt to on-site voltage fluctuation. Balanced and stable power consumption with built-in power-on soft-start circuit suppresses inrush current, fully protecting rear valves, sensors and internal electronic components and enhancing overall electrical safety and stability.
Drive & Load Capacity: Equipped with 2X enhanced drive structure with upgraded load compatibility. It matches medium and large heavy-duty hydraulic servo actuators, large-flow high-frequency proportional valves and heavy-duty servo cylinders. It adapts to high-frequency reciprocating, high-speed dynamic and heavy-load fluctuating working conditions with sufficient driving force and strong load tolerance, meeting strict drive requirements of various high-end precision hydraulic equipment.
Control Performance: Adopting upgraded full-digital multi-mode closed-loop control algorithm, it supports free switching among position, pressure, speed and flow closed-loop modes. Embedded high-precision adaptive PID regulation, feedforward dynamic compensation, friction compensation, valve lap compensation and load fluctuation compensation algorithms deliver fast response, favorable dynamic follow-up performance, ultra-low steady-state error and superior linearity. It achieves micron-level positioning accuracy as well as high-precision constant pressure and constant speed control. Optimized by A012 dedicated process program for molding, forging and precision testing scenarios, it boasts stronger process adaptability.
Signal & Bus Configuration: Compatible with standard industrial analog signals, supporting 0-10V and 4-20mA signal input and output. Fitted with upgraded E23 bus interface, it supports high-speed communication protocols including EtherCAT, Modbus TCP/IP and Profinet. It realizes high-speed data exchange, real-time parameter access, remote configuration, fault data upload and precise multi-axis synchronous control, fitting modern intelligent bus control systems.
Output Capacity: The maximum standard driving output current is 1.5A, capable of directly driving most industrial high-frequency servo proportional valves without external power amplifiers to simplify hardware structure. The output signal features high linearity, no dynamic lag and running jitter with outstanding stability.
Parameter Adjustability: Proportional, integral and differential gains are steplessly adjustable within 0-100%. Output amplitude, ramp time, limit threshold and synchronous parameters are configurable freely. Local fine tuning and remote parameter setting via upper software are available. Preset process templates of exclusive A012 program facilitate quick adaptation to different valve characteristics and production conditions.
Protection Mechanism: Comprehensive intelligent protection covers overcurrent, overvoltage, undervoltage, short circuit, overtemperature, abnormal load monitoring, signal breakage and bus fault protection. Fault codes can be locked and abnormal output cut off instantly to avoid burnout of valves, modules and complete equipment, prevent fault spread and improve system safety and reliability remarkably.
Environmental Adaptability: Wide temperature design, operating temperature: -20℃~+60℃, storage temperature: -40℃~+85℃. Operating humidity: 5%~95% non-condensing. It has excellent dustproof, moistureproof, oil-resistant, anti-aging and anti-electromagnetic interference properties, capable of stable long-term operation in harsh hydraulic sites with intense vibration, heavy dust and strong electromagnetic interference.

2.2 Physical & Structural Specifications

Installation Mode: Standard industrial DIN rail mounting fits standard layout and dense installation of electrical control cabinets. Easy and firm installation with superior vibration resistance prevents loosening and displacement during long-term operation, applicable to equipment renovation and new unit assembly.
Structural Design: Compact integrated modular structure highly integrates drive circuits, high-speed computing units, bus interfaces, signal conditioning circuits and multi-protection circuits. Small footprint saves cabinet space and suits compact electric control schemes of various automatic equipment.
Weight: Lightweight industrial design with solid structure balances stability and maintenance convenience, facilitating on-site assembly, replacement, debugging and later servicing.
Material & Protection: The shell is made of high-strength flame-retardant industrial material treated with moisture-proof, anti-corrosion and anti-aging process, featuring oil resistance, impact resistance and corrosion resistance. Multi-layer shielding internal wiring isolates external electromagnetic interference effectively and maintains pure and stable control signals without long-term parameter drift.
Interface Features: Well-divided ports include power port, analog signal port, E23 high-speed bus port and valve drive output port. Standard terminals allow convenient plugging and reliable contact with anti-loose locking structure, eliminating poor connection, wire breakage and signal anomalies caused by vibration.
Status Indication: High-definition LED indicators visually display power status, operating state, bus connection and fault alarm information, assisting staff in rapid inspection, status recognition and accurate fault location to raise maintenance efficiency.

2.3 Core Functions & Compatibility Specifications

Core Functions: Integrated full-process functions include hydraulic valve power drive, multi-mode precise closed-loop control, signal acquisition and conditioning, smooth ramp signal generation, accurate valve compensation, dynamic load adaptation, high-speed bus data interaction and intelligent fault diagnosis. Supported by 2X enhanced algorithm and A012 customized program, it precisely regulates hydraulic pressure, speed, flow and position. Functions such as parameter auto-tuning, automatic zero calibration, multi-axis coordinated control and process parameter memory satisfy diverse high-end precision hydraulic control demands.
Integration Features: The highly integrated module independently completes signal reception, operational regulation, power amplification, valve drive, bus communication and fault protection. No additional signal conversion or external amplifier modules are required, greatly simplifying wiring, reducing fault points and cutting equipment matching and maintenance costs.
Compatibility: Fully compatible with all Rexroth hydraulic servo valves, proportional valves, servo cylinders and hydraulic actuators. It connects seamlessly with PLCs, industrial controllers and upper configuration systems of all brands. Compatible with mainstream industrial bus protocols such as EtherCAT, Modbus and Profinet, it fits standard automatic control architectures and can be applied to new equipment assembly and renovation upgrading of old hydraulic facilities.
Reliability & Practicability: Industrial durable design supports 24-hour non-stop continuous operation with negligible long-term parameter drift and high stability. Online parameter modification, real-time curve monitoring and fault log storage and query enable maintenance without disassembly, shortening downtime and improving overall production efficiency.

3. Working Principle

System Initialization & Parameter ConfigurationAfter power-on, the module automatically conducts hardware self-test, circuit inspection, E23 bus scanning and port verification. It fully checks power supply, internal circuits, communication ports and rear load status and enters standby state when no abnormality is detected. Operators select control modes and set PID values, ramp time, output amplitude, protection thresholds and multi-axis synchronous parameters accurately via local trim terminals, upper software or PLC bus combined with built-in A012 process templates to match on-site valve characteristics and actual production conditions.

Command Reception & Signal Processing

The module receives real-time position, pressure, speed and flow setting commands from upper systems, and collects actual operating feedback signals from on-site sensors simultaneously. Internal high-precision filtering eliminates electromagnetic interference and noise, purifies input data and calculates deviations between set values and actual operating data accurately to provide reliable basis for closed-loop calculation.

Closed-loop Calculation & Drive Output

Based on preset control modes, the 2X enhanced high-speed computing algorithm executes adaptive PID regulation, ramp smoothing, valve compensation and dynamic load correction. Output power and driving current are adjusted precisely in real time and amplified by internal power circuits to drive hydraulic proportional and servo valves accurately. Operational deviations are corrected rapidly to realize stable and high-precision dynamic follow-up control of hydraulic pressure, speed, position and flow.

Bus Interaction & Multi-axis Coordinated Control

Two-way real-time data exchange is realized with upper control systems via E23 high-speed bus. Module operating status, output parameters, hydraulic data and fault information are uploaded continuously while control commands are received instantly. Multi-module clock synchronization enables precise coordinated movement of multi-axis equipment, meeting synchronous control requirements of complex automatic production lines and sophisticated processes.

Real-time Monitoring & Intelligent Fault Protection

Power voltage, output current, module temperature, bus connection, load condition and signal transmission are monitored throughout operation. Once faults including overcurrent, overvoltage, overtemperature, short circuit, signal breakage, abnormal load and bus failure are detected, fault codes will be locked automatically, power output cut off and audible and visual alarms triggered to protect valves, modules and complete equipment and prevent fault escalation.

Online Debugging & Maintenance Optimization

Online parameter tuning, real-time waveform observation, dynamic parameter optimization and automatic zero calibration help obtain optimal control parameters rapidly for different working conditions. Large-capacity built-in fault log stores long-term operating and fault data, facilitating quick troubleshooting, equipment status analysis, efficient maintenance and continuous performance improvement.

4. Application Scenarios

4.1 High-end Precision Hydraulic Machine Tools

Widely used in high-precision CNC hydraulic machine tools, precision grinders and hydraulic finishing equipment. Supported by high-precision closed-loop control and 2X enhanced algorithm, it accurately adjusts feed speed, cutting pressure, oil flow and positioning stroke, greatly improving machining accuracy, repetitive positioning precision and product consistency to meet stringent requirements of sophisticated mechanical processing.

4.2 Injection & Die-casting Industry

Suitable for high-end injection molding machines, die-casting machines and rubber molding equipment. With the aid of A012 exclusive molding process program, it precisely controls pressure and speed during mold clamping, injection, pressure holding, pressure relief and mold opening procedures. Stable technological parameters reduce defects such as shrinkage, burr, deformation and air bubbles, remarkably raising product yield and production stability.

4.3 Forging & Heavy-duty Hydraulic Machinery

Applied to hydraulic forging presses, precision presses, high-speed punching machines and bending machines. With 2X enhanced load adaptability, it adapts to heavy-load, high-frequency and high-pressure impact conditions, realizing constant pressure control, accurate stroke speed regulation and adaptive load adjustment, and ensuring safe, stable and evenly powered operation of heavy machinery.

4.4 Precision Industrial Testing & Experimental Equipment

Applicable to various high-end hydraulic test benches, component fatigue testing machines, pressure inspection devices and precision pressure regulating systems. It achieves high-precision dynamic regulation and long-term steady condition maintenance of pressure, flow and speed, satisfying core demands of accurate data, stable operation, traceable parameters and high repeatability for testing equipment.

4.5 Automated Multi-axis Synchronous Hydraulic Production Lines

Leveraging E23 high-speed bus and multi-axis synchronous control functions, it is extensively applied to automatic hydraulic production lines, hydraulic manipulators, synchronous lifting platforms and intelligent hydraulic control systems. Precise coordinated movement of multiple devices and axes unifies production rhythm and improves operational efficiency, synchronization accuracy and overall stability of automatic lines.