Description

REXRTOH SYHNC100-NIB-24-P-D-E23-A012 R900978416

1. Basic Information

REXROTH SYHNC100-NIB-24-P-D-E23-A012 (Order No.: R900978416) is a single-axis full-digital hydraulic servo control unit and a classic high-precision hydraulic closed-loop intelligent controller. It eliminates redundant extended configurations and focuses on core demands of single-axis hydraulic precision control. Equipped with E23 high-speed bus architecture and customized A012 process program, it is developed for standard precision hydraulic molding, heavy-duty forging, high-frequency reciprocating operation and high-accuracy testing equipment. It realizes stable full closed-loop dynamic precise regulation of four parameters including position, pressure, speed and flow for single hydraulic actuator. It is widely applicable to standard CNC hydraulic machine tools, conventional injection and die-casting molding equipment, general heavy-duty forging machinery, single-axis hydraulic automated devices and precision testing systems.

Adopting industrial-grade DSP full-digital high-speed computing structure, the module highly integrates high-precision signal acquisition and conditioning, multi-mode adaptive PID closed-loop calculation, dynamic load compensation, friction compensation, valve lap compensation, power drive amplification, industrial bus communication and comprehensive fault diagnosis and protection functions. It can directly drive various common high-frequency servo proportional valves, servo hydraulic cylinders and hydraulic servo motors. As a standard universal model of the series, the 24-version hardware circuit is optimized through mass production with stable operation, reliable working condition adaptability and strong anti-interference performance. Matched with 24VDC standard industrial power supply, E23 multi-protocol high-speed bus and exclusive A012 program, it features fast dynamic response, high control resolution and superior steady-state precision. It perfectly adapts to harsh working scenarios such as conventional high-frequency reciprocating impact, medium heavy load fluctuation, micron-level precise positioning and high-accuracy constant pressure & speed control. It fundamentally resolves common drawbacks of traditional analog hydraulic control including temperature drift, zero offset, signal lag and weak anti-interference capability, effectively improving machining consistency, operational stability and finished product yield. It serves as a highly versatile and reliable standardized core control component in industrial hydraulic control field.

Built with industrial reinforced modular DIN rail structure, the unit features compact and sturdy design with excellent vibration, dust, oil and electromagnetic resistance. The standardized universal interface layout supports quick replacement, integration and renovation of new and old equipment, and achieves seamless connection with PLCs, industrial controllers and upper monitoring systems of Siemens, Mitsubishi, Omron and other brands. It supports programmable parameter configuration, real-time online debugging, parameter auto-tuning, adaptive zero calibration and intelligent fault self-diagnosis. Suitable for 24-hour non-stop continuous operation, it runs steadily under complex hydraulic conditions with heavy dust, intense vibration and strong electromagnetic interference, widely applied to high-precision drive and regulation of various standard single-axis hydraulic automatic control systems.

2. Technical Specifications

2.1 Core Electrical & Control Specifications

Power Supply: Adopts standard 24VDC industrial control power supply with stable operating voltage ranging from 18VDC to 30VDC, adapting to complex on-site conditions including grid voltage fluctuation and line voltage drop. It maintains balanced and stable power consumption without abnormal heat generation or power deviation during long-term operation. The built-in power-on soft-start circuit effectively suppresses instantaneous inrush current, fully protects rear hydraulic valve groups, detection sensors and internal precision computing circuits, and enhances overall electrical safety and long-term stability of hydraulic control systems.
Drive & Load Capacity: Based on optimized 24-version standard hardware, the load coverage fits general industrial working conditions. It stably matches medium and small heavy-duty hydraulic servo actuators, regular large-flow high-frequency proportional valves and standard heavy-load servo cylinders, and operates persistently under mainstream industrial conditions of high-frequency reciprocation, high-speed movement, heavy load fluctuation and high-pressure impact. It delivers sufficient driving force, high load tolerance and wide applicability, meeting heavy-load and high-precision driving requirements of various standard high-end precision hydraulic equipment.
Control Performance: Equipped with dedicated Rexroth multi-mode hydraulic control algorithm, it supports free switching among position, pressure, speed and flow closed-loop modes to satisfy all types of hydraulic process control demands. Embedded high-precision adaptive PID regulation, feedforward dynamic compensation, friction compensation, valve lap compensation and adaptive load fluctuation compensation algorithms ensure rapid dynamic response, excellent tracking performance, minimal steady-state error and perfect control linearity. It achieves stable micron-level precise positioning and high-accuracy constant pressure and speed control. Optimized by exclusive A012 program for molding, forging and precision testing scenarios, its process adaptability and control accuracy are verified by mass production with stronger compatibility and more stable operation.
Signal & Bus Configuration: Compatible with standard industrial analog signals, supporting 0-10V voltage and 4-20mA current input and output with accurate signal collection and stable transmission. Equipped with upgraded E23 high-speed bus interface compatible with EtherCAT, Modbus TCP/IP, Profinet and other mainstream industrial protocols, it enables high-speed bidirectional data exchange, real-time parameter access, remote configuration, fault data upload and precise synchronous control, perfectly fitting modern intelligent bus-based hydraulic automatic control systems.
Output Capacity: The maximum rated driving output current is 1.5A. The output signal features high linearity, no dynamic lag, running jitter or low-frequency drift with stable and balanced performance. It directly drives most industrial high-frequency servo proportional valves without external power amplifiers, simplifying hardware structure, reducing fault points and lowering equipment matching and maintenance costs.
Parameter Adjustability: Proportional, integral and differential gains are steplessly adjustable from 0 to 100%. Core parameters including output amplitude, ramp rise & fall time, limit thresholds, alarm thresholds and synchronous operating parameters are freely configurable. Local terminal fine tuning and remote parameter setting via upper software are available. Built-in general process templates in A012 program facilitate quick matching with different valve characteristics and actual working conditions for convenient and efficient commissioning suitable for most conventional hydraulic equipment.
Protection Mechanism: Complete multi-intelligent protection functions cover overcurrent, overvoltage, undervoltage, short circuit, overtemperature, abnormal load, analog signal breakage, bus fault and hardware self-check protection. Fault codes are locked instantly, abnormal output cut off and alarms triggered timely to fully protect valves, modules and complete equipment, prevent fault spread and burnout, and guarantee long-term safe and stable operation of hydraulic systems.
Environmental Adaptability: Wide temperature design, operating temperature: -20℃~+60℃, storage temperature: -40℃~+85℃. Operating humidity: 5%~95% non-condensing. It possesses outstanding dustproof, moistureproof, oil-resistant, anti-aging and anti-electromagnetic interference properties, running steadily in harsh hydraulic sites with severe vibration, heavy dust and strong electromagnetic interference and covering all kinds of conventional industrial production scenarios.

2.2 Physical & Structural Specifications

Installation Mode: Supports standard industrial DIN rail mounting, suitable for standard layout and dense installation of electrical control cabinets. Easy installation and firm fixation deliver excellent vibration resistance against long-term high-frequency operation vibration without loosening, displacement or poor contact, perfectly applicable to renovation, upgrading and new assembly of old and new single-axis hydraulic equipment.
Structural Design: Compact integrated modular structure highly incorporates high-speed computing unit, high-precision signal conditioning circuit, power drive circuit, E23 bus interface, multi-functional signal ports and multi-protection circuits. Small size, neat layout and high integration save cabinet space greatly, fitting compact electric control schemes of various high-end hydraulic equipment with strong versatility.
Weight: Lightweight industrial design with sturdy portable body, balancing overall equipment stability and convenience of on-site assembly, replacement, debugging and maintenance for compact installation of various single-axis hydraulic devices.
Material & Protection: The shell adopts high-strength flame-retardant industrial material treated with moisture-proof, anti-corrosion, anti-aging and oil-resistant processes, featuring impact resistance and long service life. Internal circuits apply multi-layer shielded wiring to isolate external electromagnetic interference effectively, maintaining pure and stable control signals without parameter drift or performance degradation during continuous operation.
Interface Features: Well-divided independent ports include 24VDC power port, analog signal port, E23 high-speed bus port and valve drive output port with clear functions and isolated strong & weak electricity without mutual interference. Standard terminals enable convenient plugging and reliable connection with anti-loose locking structure, eliminating poor contact, wire breakage and signal anomalies caused by equipment vibration.
Status Indication: High-definition LED indicators visually display power supply status, running state, bus connection, signal transmission and fault alarm, facilitating rapid on-site inspection, status identification and accurate fault location to improve maintenance efficiency.

2.3 Core Functions & Compatibility Specifications

Core Functions: Integrated full-process functions include hydraulic valve power drive, single-axis multi-mode precise closed-loop control, high-precision signal acquisition and conditioning, smooth ramp signal generation, accurate valve compensation, dynamic load adaptation, E23 high-speed data interaction and intelligent fault diagnosis. Supported by stable 24-version hardware and customized A012 program, it accurately regulates pressure, speed, flow and position of hydraulic systems, and enables parameter auto-tuning, automatic zero calibration, process parameter storage and precise single-axis closed-loop control, fully meeting control demands of various high-end precision single-axis hydraulic processes.
Integration Features: Highly integrated design allows the single module to independently complete signal reception, logic calculation, closed-loop 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 for mass-produced equipment.
Compatibility: Fully compatible with all Rexroth hydraulic servo valves, proportional valves, servo hydraulic cylinders and conventional hydraulic actuators. It connects seamlessly with PLCs, industrial controllers and upper monitoring systems from Siemens, Mitsubishi, Omron and other manufacturers. Supporting EtherCAT, Modbus, Profinet and other mainstream industrial bus protocols, it adapts to standard automatic control architectures and applies to new equipment assembly and old single-axis hydraulic system upgrading.
Reliability & Practicability: Industrial durable design supports 24-hour non-stop continuous operation with negligible long-term parameter drift, high stability, low failure rate and no performance degradation. Online parameter modification, real-time curve monitoring and fault log storage & query are available. Maintenance can be carried out without disassembly, shortening downtime and improving overall production efficiency and continuity for mass production scenarios.

3. Working Principle

System Initialization & Parameter ConfigurationAfter power-on, the module conducts comprehensive hardware self-test, circuit inspection, E23 bus scanning and port signal verification to check power supply, internal computing circuits, communication ports and rear load status, and enters standby mode with no abnormality detected. Operators select control modes and set PID parameters, ramp time, output amplitude and protection thresholds via local terminals, dedicated upper debugging software or PLC bus combined with built-in A012 process templates, matching on-site valve characteristics and actual working conditions.

Command Reception & Signal Processing

The module receives real-time position, pressure, speed and flow set commands from upper control systems, and collects actual operating feedback signals from on-site high-precision sensors simultaneously. Internal high-precision filtering eliminates electromagnetic interference, power clutter and environmental noise to purify input data. Deviations between set values and actual operating values are calculated accurately to provide reliable data support for high-speed closed-loop calculation.

Closed-loop Calculation & Drive Output

Based on preset control logic, the unit executes adaptive PID regulation, ramp smoothing, accurate valve compensation and dynamic load correction relying on high-speed computing capability and optimized universal algorithms of 24-version hardware. Output power and driving current are adjusted dynamically and amplified by internal power circuit 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, ensuring consistent and stable process operation.

Bus Interaction & Coordinated Control

Real-time bidirectional data exchange is realized with upper systems through E23 high-speed bus. Operating status, output parameters, hydraulic data and fault information are uploaded continuously, while control commands are received instantly. Multi-module clock synchronization and data linkage enable coordinated movement of multi-axis equipment, satisfying synchronous control requirements of conventional automatic lines and precision molding processes.

Real-time Monitoring & Intelligent Fault Protection

Overall power voltage, output current, module temperature, bus connection and load conditions are monitored throughout operation. Once faults such as overcurrent, overvoltage, overtemperature, short circuit, signal breakage, abnormal load and bus failure are detected, fault codes will be locked, power output cut off and alarms triggered immediately to fully protect hydraulic valves, control module 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 acquire optimal control parameters for diverse working conditions. Large-capacity fault log records long-term operating and fault data, facilitating rapid troubleshooting, operational status analysis, efficient maintenance and continuous performance improvement.

4. Application Scenarios

4.1 High-end Precision Hydraulic Machine Tools

Widely used in standard CNC hydraulic machine tools, precision hydraulic grinders and hydraulic finishing equipment. Leveraging stable high-precision computing performance and optimized closed-loop algorithms of 24-version hardware, it accurately adjusts feed speed, cutting pressure, oil flow and positioning stroke, greatly enhancing machining precision, repetitive positioning accuracy and finished product consistency to meet strict process standards of high-end precision mechanical processing and fit mass precision production.

4.2 High-end Injection & Die-casting Industry

Applicable to conventional high-end injection molding machines, die-casting machines, rubber molding machines and precision die-casting equipment. With the aid of exclusive A012 molding program, it precisely controls pressure and speed throughout mold clamping, injection, pressure holding, pressure relief and mold opening procedures to stabilize process parameters. It effectively reduces molding defects including shrinkage, burr, deformation, air bubbles and material shortage, improving product yield and stable production rhythm for mass molding production.

4.3 Heavy-duty Forging Hydraulic Machinery

Mainly applied to conventional hydraulic forging presses, precision presses, high-speed punching machines, bending machines and hydraulic shaping units. Featuring excellent heavy-load adaptability and impact resistance of 24-version hardware, it adapts to heavy-load, high-frequency and high-pressure impact conditions. It realizes constant pressure control, precise stroke speed regulation and adaptive load adjustment, ensuring safe, stable and evenly powered operation of heavy machinery and fitting most general forging equipment working conditions.

4.4 Precision Industrial Testing Equipment

Suitable for various high-end hydraulic test benches, component fatigue testing machines, material pressure inspection devices, precision pressure regulating systems and dynamic hydraulic testing equipment. It achieves high-precision dynamic regulation and long-term steady state maintenance of pressure, flow, speed and position, meeting core requirements of accurate data, stable operation, traceable parameters and high repeatability for testing devices verified by numerous practical tests.

4.5 Automated Single-axis Hydraulic Equipment & General Production Lines

Supported by stable closed-loop control and E23 high-speed bus communication, it is extensively applied to single-axis hydraulic automated devices, conventional hydraulic manipulators, standard hydraulic lifting platforms, intelligent hydraulic control systems and ordinary automatic hydraulic lines. It accurately controls operational rhythm and ensures stable running and parameters, significantly boosting working efficiency and overall stability, acting as a universal core component for industrial hydraulic automation upgrading.