Description

REXRTOH SYHNC100-NIB-2X/W-24-P-D-E23-A012 R900978416

1. Basic Information

This is a dual-axis full-digital hydraulic servo control module, an industrial multi-axis synchronous hydraulic closed-loop intelligent control unit. Different from single-axis models, it adopts 2X independent dual-axis hardware architecture to support synchronous and independent precise regulation of two hydraulic axes. Equipped with E23 high-speed multi-protocol bus and exclusive A012 high-end molding process program, it is developed for multi-axis synchronous hydraulic molding, heavy-duty forging, high-frequency reciprocating machinery and multi-station precision testing systems. It achieves full closed-loop dynamic regulation of four parameters including position, pressure, speed and flow for two hydraulic actuators simultaneously. It is widely applicable to multi-axis CNC hydraulic machine tools, dual-station injection and die-casting equipment, synchronous forging machinery, automatic multi-axis hydraulic production lines and precision synchronous testing systems.

The module adopts industrial-grade DSP full-digital high-speed dual-core computing structure with two completely independent and non-interfering control channels. It highly integrates dual-channel high-precision signal acquisition and conditioning, multi-mode adaptive PID closed-loop calculation, dynamic load compensation, friction compensation, valve lap compensation, dual-channel power drive amplification, high-speed bus communication and comprehensive fault diagnosis and protection functions. It can drive two sets of high-frequency servo proportional valves, servo hydraulic cylinders and hydraulic servo motors concurrently. The 2X series hardware is a standardized universal multi-axis platform of Rexroth, fully compatible with all versions from 20 to 29 in mounting dimension and electrical interface. Its circuit anti-interference, multi-axis synchronous calculation and heavy load adaptability are specially optimized. Matched with 24VDC standard industrial power supply, E23 multi-protocol high-speed bus and A012 dedicated program, the module features superior dual-axis dynamic synchronization, high control resolution and ultra-low steady-state error. It effectively solves common industry problems of traditional multi-axis hydraulic control such as poor synchronization, parameter drift, signal lag, weak anti-interference and complicated commissioning, and greatly improves operational consistency, process stability and finished product yield of multi-axis equipment.

Built with industrial reinforced modular DIN rail structure, the unit features compact and sturdy design, excellent vibration, dust, oil and electromagnetic resistance. The standardized universal interface layout enables quick replacement, integration and renovation of new and old equipment, and realizes seamless connection with PLCs, industrial controllers and upper monitoring systems of Siemens, Mitsubishi, Omron and other brands. It supports independent programmable dual-axis parameter configuration, real-time synchronous online debugging, dual-axis 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, serving as the core high-precision drive and control unit of high-end multi-axis synchronous 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 synchronous power consumption of dual axes without abnormal heat generation or power deviation. The built-in power-on soft-start suppression circuit effectively reduces instantaneous inrush current, fully protects rear dual-channel hydraulic valve groups, detection sensors and internal precision computing circuits, and enhances overall electrical safety and long-term operational stability of multi-axis systems.
Drive & Load Capacity: Based on optimized 2X dedicated dual-axis hardware, two channels operate independently without load coupling interference. Each channel matches medium and large heavy-duty hydraulic servo actuators, large-flow high-frequency proportional valves and heavy-load servo cylinders, and operates persistently under harsh working conditions of high-frequency reciprocation, high-speed movement, heavy load fluctuation and high-pressure impact. It delivers sufficient driving force and consistent load tolerance for both axes, meeting heavy-load, high-precision and high-synchronization driving requirements of various high-end multi-axis synchronous hydraulic equipment.
Control Performance: Equipped with dedicated Rexroth dual-axis synchronous multi-mode hydraulic control algorithm, two axes can be controlled independently. Each axis 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 adaptive load fluctuation compensation algorithms ensure high synchronous dynamic response accuracy, superior tracking performance, minimal steady-state error and perfect control linearity. It realizes micron-level precise synchronous positioning and high-precision constant pressure & speed coordinated control for dual axes. Optimized by exclusive A012 multi-axis molding program for synchronous molding, forging and precision testing scenarios, the module achieves greatly improved process adaptability and synchronous control accuracy.
Signal & Bus Configuration: Two independent channels are compatible with standard industrial analog signals, supporting 0-10V voltage and 4-20mA current input and output with no crosstalk between channels. 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, independent parameter access, remote synchronous configuration, fault data upload and precise multi-axis synchronous linkage control, fitting modern intelligent bus-based multi-axis hydraulic automatic control systems.
Output Capacity: The maximum rated driving output current per channel is 1.5A. Dual channels feature high parameter consistency, excellent linearity, no dynamic lag, running jitter or low-frequency drift. It directly drives two industrial high-frequency servo proportional valves simultaneously without external power amplifiers, simplifying hardware structure, reducing fault points and lowering equipment matching and commissioning costs.
Parameter Adjustability: Proportional, integral and differential gains of dual axes are steplessly adjustable from 0 to 100% independently. Single-axis output amplitude, ramp rise & fall time, upper and lower limit thresholds, alarm thresholds and multi-axis synchronous deviation thresholds are freely configurable. Local single-axis fine tuning and remote dual-axis synchronous parameter setting via upper software are available. Built-in multi-axis synchronous process templates in A012 program facilitate quick matching with different valve characteristics and actual working conditions for efficient commissioning.
Protection Mechanism: Complete multi-intelligent protection functions are equipped for dual channels. Each axis independently provides overcurrent, overvoltage, undervoltage, short circuit, overtemperature, abnormal load, analog signal breakage, bus fault and hardware self-check protection. Fault codes are locked independently, abnormal output of the corresponding axis cut off and alarms triggered instantly. Fault of one axis will not affect basic operation of the other, preventing burnout of valves, modules and complete equipment, avoiding fault spread and ensuring full-range safety of multi-axis systems.
Environmental Adaptability: Wide temperature design, operating temperature: -20℃~+60℃, storage temperature: -40℃~+85℃. Operating humidity: 5%~95% non-condensing. It boasts outstanding dustproof, moistureproof, oil-resistant, anti-aging and anti-electromagnetic interference properties. Dual-axis computing circuits have strong anti-crosstalk capability for stable long-term operation in harsh hydraulic sites with severe vibration, heavy dust and strong electromagnetic interference.

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. Fully compatible with all mounting sizes of 2X series, it applies to renovation, upgrading and new assembly of old and new multi-axis hydraulic equipment.
Structural Design: Compact integrated dual-axis modular structure highly incorporates dual high-speed computing units, dual high-precision signal conditioning circuits, dual power drive circuits, E23 bus interface, multi-functional signal ports and multi-protection circuits. Small size, neat layout and isolated dual channels save cabinet space greatly, fitting compact electric control schemes of high-end multi-axis hydraulic equipment.
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 multi-axis 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 dual-axis circuits apply independent partition and multi-layer shielded wiring to thoroughly isolate inter-axis crosstalk and external electromagnetic interference, maintaining pure and stable control signals without parameter drift or accumulated synchronous deviation during continuous operation.
Interface Features: Well-divided independent ports include 24VDC power port, dual independent analog signal ports, E23 high-speed bus port and dual independent valve drive output ports with clear functions and no 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, overall running state, bus connection, independent operating status of two axes, signal transmission and single-axis fault alarm respectively. It facilitates rapid on-site inspection, dual-axis status identification and accurate single-axis fault location to improve multi-axis equipment maintenance efficiency.

2.3 Core Functions & Compatibility Specifications

Core Functions: Integrated full-process functions include dual hydraulic valve power drive, dual-axis multi-mode precise closed-loop control, dual high-precision signal acquisition and conditioning, smooth ramp signal generation, accurate valve compensation, dynamic load adaptation, E23 high-speed multi-axis data interaction and intelligent fault diagnosis. Supported by optimized 2X dual-axis hardware and customized A012 multi-axis process program, it independently and accurately regulates pressure, speed, flow and position of two hydraulic systems. It enables parameter auto-tuning, automatic zero calibration, precise multi-axis synchronous coordinated control and process parameter storage, fully meeting control demands of various high-end multi-axis synchronous precision hydraulic processes.
Integration Features: Highly integrated dual-axis design allows the single module to independently complete signal reception, logic calculation, closed-loop regulation, power amplification, valve drive, bus communication and fault protection for two channels. No additional dual-axis expansion, 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 hydraulic cylinders and hydraulic actuators, two axes can be matched with valves of identical or different specifications. 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 multi-axis automatic control architectures and applies to new equipment assembly and old multi-axis hydraulic system upgrading.
Reliability & Practicability: Industrial durable design supports 24-hour non-stop continuous operation with negligible long-term parameter drift, stable synchronization accuracy, low failure rate and no performance degradation. Independent online parameter modification, real-time synchronous curve monitoring and separate fault log storage & query are available. Maintenance can be carried out without disassembly, shortening downtime and improving overall production efficiency and continuity of multi-axis automatic lines.

3. Working Principle

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

Dual-axis Command Reception & Signal Processing

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

Dual-axis Closed-loop Calculation & Drive Output

Based on preset dual-axis control logic, two computing units execute adaptive PID regulation, ramp smoothing, accurate valve compensation and dynamic load correction relying on high-speed parallel computing capability and optimized synchronous algorithms of 2X hardware. Output power and driving current of each axis are adjusted dynamically and amplified by internal dual power circuits to drive hydraulic proportional and servo valves accurately. Operational deviations are corrected rapidly to realize stable and high-precision synchronous dynamic follow-up control of hydraulic pressure, speed, position and flow for dual axes, ensuring consistent and stable multi-axis process operation.

Bus Interaction & Multi-axis Coordinated Control

Real-time bidirectional data exchange is realized with upper systems through E23 high-speed bus. Independent operating status, output parameters, hydraulic data and fault information of two axes are uploaded continuously, while dual-axis regulation, synchronous linkage and single-axis independent control commands are received instantly. Multi-module clock synchronization and data linkage enable precise coordinated movement of multiple devices and axes, satisfying control requirements of complex automatic multi-axis lines and precision synchronous molding processes.

Real-time Dual-axis Monitoring & Intelligent Fault Protection

Overall power voltage, dual-axis output current, module temperature, bus connection and load conditions of two channels are monitored throughout operation. Single-axis faults are identified independently with corresponding fault codes locked, power output of the faulty axis cut off and alarms triggered separately. Fault isolation ensures normal operation of the other axis, fully protecting dual hydraulic valve groups, control module and complete equipment and preventing fault escalation.

Online Dual-axis Debugging & Maintenance Optimization

Independent online parameter tuning, real-time synchronous waveform observation, dynamic parameter optimization and automatic dual-axis zero calibration help acquire optimal synchronous control parameters for diverse working conditions. Large-capacity separate fault log records long-term operating and fault data of two channels, facilitating rapid single-axis troubleshooting, multi-axis synchronization status analysis, efficient maintenance and continuous performance improvement.

4. Application Scenarios

4.1 High-end Multi-axis Precision Hydraulic Machine Tools

Widely used in dual-axis synchronous CNC hydraulic machine tools, precision dual-axis hydraulic grinders and multi-axis hydraulic finishing equipment. Leveraging high-precision parallel computing performance and optimized synchronous closed-loop algorithms of 2X hardware, it accurately adjusts dual-axis feed speed, cutting pressure, oil flow and positioning synchronization accuracy, greatly enhancing machining precision, repetitive positioning accuracy and finished product consistency to meet strict process standards of high-end precision multi-axis mechanical processing.

4.2 High-end Dual-station Injection & Die-casting Industry

Applicable to dual-station injection molding machines, dual-mold die-casting machines, multi-station rubber molding machines and precision synchronous die-casting equipment. With the aid of exclusive A012 multi-axis molding program, it precisely controls pressure and speed throughout mold clamping, injection, pressure holding, pressure relief and mold opening procedures of two axes, ensuring highly consistent process parameters of dual stations. It effectively reduces molding defects including shrinkage, burr, deformation, air bubbles and material shortage, improving batch product yield and stable production rhythm of multi-station lines.

4.3 Multi-axis Synchronous Heavy-duty Forging Hydraulic Machinery

Mainly applied to dual-axis synchronous hydraulic forging presses, double-column precision presses, symmetrical high-speed punching machines, synchronous bending machines and hydraulic shaping units. Featuring excellent heavy-load adaptability, impact resistance and high synchronization of 2X hardware, it adapts to synchronous heavy-load, high-frequency and high-pressure impact conditions. It realizes synchronous constant pressure control, precise stroke speed regulation and adaptive load adjustment, ensuring safe, stable, evenly powered and deviation-free synchronous operation of heavy multi-axis equipment.

4.4 Dual-station Precision Synchronous Industrial Testing Equipment

Suitable for various dual-station synchronous hydraulic test benches, dual-channel component fatigue testing machines, symmetrical material pressure inspection devices, precision synchronous pressure regulating systems and dynamic multi-axis hydraulic testing equipment. It achieves high-precision synchronous dynamic regulation and long-term steady state maintenance of pressure, flow, speed and position, meeting core requirements of symmetrical accurate data, stable synchronous operation, traceable parameters and high repeatability for multi-station testing devices.

4.5 Automatic Multi-axis Synchronous Hydraulic Production Lines

Supported by 2X independent dual-axis control, E23 high-speed bus and precise multi-axis synchronous control functions, it is extensively applied to automatic multi-axis hydraulic lines, dual-manipulator hydraulic linkage systems, synchronous lifting platforms, intelligent multi-axis hydraulic control systems and multi-station linkage hydraulic automatic equipment. It realizes precise coordinated movement of multiple axes and unified production rhythm, significantly boosting operational efficiency, synchronization accuracy and overall stability of automatic lines.