Description

REXRTOH SYHNC100-NIB-23/W-24-P-D-E23-A012 R900978416

1. Basic Information

This product is a full-digital hydraulic axis control drive module and industrial high-precision hydraulic servo closed-loop intelligent control unit. Equipped with E23 high-speed bus architecture and A012 customized process program, it is developed for high-end precision hydraulic molding, heavy-duty forging, high-frequency reciprocating operation and high-precision testing equipment. It realizes stable full closed-loop dynamic accurate regulation of four parameters including position, pressure, speed and flow of hydraulic actuators, and is widely applicable to CNC hydraulic machine tools, injection and die-casting molding equipment, heavy-duty forging machinery, automatic multi-axis hydraulic production lines and precision testing systems.

Adopting industrial-grade DSP full-digital high-speed computing framework, 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 high-frequency servo proportional valves, servo hydraulic cylinders and hydraulic servo motors. Compared with conventional models, the Version 23 hardware circuit is optimized and upgraded with improved anti-interference capability, operational stability and load adaptability. Matched with 24VDC standard industrial power supply, E23 multi-protocol high-speed bus and exclusive A012 process program, it features faster dynamic response, higher control resolution and better steady-state control accuracy. It perfectly adapts to severe working conditions such as high-frequency reciprocating impact, heavy load fluctuation, micron-level precision positioning and high-precision constant pressure & speed control. It effectively eliminates common defects of traditional analog hydraulic control including temperature drift, zero offset, signal lag and weak anti-interference, and greatly improves machining consistency, operational stability and finished product yield.

It adopts industrial reinforced modular design with compact and sturdy structure and excellent vibration, dust and oil resistance. The standardized interface layout supports rapid on-site integration and renovation, and achieves seamless connection with PLCs, industrial controllers and upper monitoring systems of all 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 long-term continuous operation, it runs steadily in complex hydraulic sites with heavy dust, intense vibration and strong electromagnetic interference, serving as the core high-precision drive and control unit of high-end hydraulic automatic multi-axis synchronous 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 on-site grid voltage fluctuation and pressure drop deviation. The module features balanced and stable power consumption without abnormal heat generation. The built-in power-on soft-start suppression circuit effectively reduces instantaneous inrush current, fully protects rear hydraulic valve groups, detection sensors and internal precision components, and enhances overall system electrical safety and long-term operational stability.
Drive & Load Capacity: Supported by optimized Version 23 drive hardware, it covers wider load range and delivers more stable driving performance. It fits medium and large heavy-duty hydraulic servo actuators, large-flow high-frequency proportional valves and heavy-duty servo cylinders. It operates persistently under harsh conditions of high-frequency reciprocation, high-speed movement, heavy load fluctuation and high-pressure impact. With sufficient driving force and strong load tolerance, it meets heavy-load high-precision driving demands of various high-end 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. Embedded high-precision adaptive PID regulation, feedforward dynamic compensation, friction compensation, valve lap compensation and adaptive load fluctuation compensation algorithms deliver rapid dynamic response, superior tracking performance, ultra-low steady-state error and perfect control linearity, enabling micron-level precision positioning and high-precision constant pressure & speed control. Optimized specially for molding, forging and precision testing scenarios by A012 exclusive program, it achieves higher process adaptability and control accuracy.
Signal & Bus Configuration: Compatible with standard industrial analog signals, supporting 0-10V voltage and 4-20mA current input and output. Fitted with upgraded E23 high-speed bus interface, it supports mainstream protocols including EtherCAT, Modbus TCP/IP and Profinet. It realizes high-speed bidirectional data exchange, real-time parameter reading and writing, remote configuration, fault data upload and precise multi-axis synchronous control, matching modern intelligent bus-based hydraulic automatic control systems.
Output Capacity: The maximum rated driving output current is 1.5A. The output signal has high linearity, no dynamic lag, no running jitter and no low-frequency drift. It directly drives most industrial high-frequency servo proportional valves without external power amplifiers, simplifying hardware structure, reducing fault points and cutting equipment matching costs.
Parameter Adjustability: Proportional, integral and differential gains are steplessly adjustable within 0-100%. Output amplitude, ramp rise & fall time, upper and lower limit thresholds, alarm thresholds and multi-axis synchronous parameters are configurable freely. Local terminal fine tuning and remote parameter setting via upper software are available. Pre-set process templates built in A012 program facilitate quick adaptation to different valve characteristics and actual working conditions for convenient and efficient commissioning.
Protection Mechanism: Complete multi-intelligent protection covers overcurrent, overvoltage, undervoltage, short circuit, overtemperature, abnormal load monitoring, analog signal breakage protection, bus fault protection and hardware self-check protection. Fault codes are locked instantly, abnormal output cut off and alarms triggered to avoid burnout of valves, modules and complete equipment, prevent fault propagation and guarantee full-range system operational safety.
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, capable of long-term stable operation in harsh hydraulic industrial 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. It is easy to install and firmly fixed with excellent vibration resistance, resisting vibration generated by long-term high-frequency operation without loosening, displacement or poor contact. It is applicable to renovation, upgrading and new assembly of various equipment.
Structural Design: Compact integrated modular structure highly integrates high-speed computing unit, high-precision signal conditioning circuit, power drive circuit, E23 bus interface, multi-functional signal ports and multi-protection circuits. It features small size and neat layout to save cabinet space, fitting compact electric control integration schemes of high-end hydraulic equipment.
Weight: Lightweight industrial design with sturdy and portable body, balancing overall equipment stability and convenience of on-site assembly, replacement, debugging and maintenance for compact installation occasions.
Material & Protection: The shell is made of high-strength flame-retardant industrial material treated with moisture-proof, anti-corrosion, anti-aging and oil-resistant processes, featuring impact resistance, corrosion resistance and long service life. Internal multi-layer shielded wiring isolates external electromagnetic interference effectively, maintaining pure and stable control signals without parameter drift during continuous long-term 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 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, equipment running state, bus connection, signal transmission and fault alarm information, 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, 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 bus data interaction and intelligent fault diagnosis. Supported by optimized Version 23 hardware and A012 customized program, it precisely regulates hydraulic pressure, speed, flow and position. It enables parameter auto-tuning, automatic zero calibration, multi-axis coordinated synchronous control and process parameter storage to meet diverse high-end precision hydraulic control requirements.
Integration Features: The highly integrated module independently completes 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 lowering 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 Siemens, Mitsubishi, Omron and other brands of PLCs, industrial controllers and upper monitoring systems. Supporting EtherCAT, Modbus, Profinet and other mainstream bus protocols, it adapts to standard automatic control architectures and can be applied to new equipment assembly and old hydraulic system upgrading projects.
Reliability & Practicability: Industrial durable design supports 24-hour non-stop continuous operation with negligible long-term parameter drift, high stability and low failure rate. Online parameter modification, real-time curve monitoring and fault log storage & query allow maintenance without disassembly, shortening downtime and improving overall production efficiency and continuity.

3. Working Principle

System Initialization & Parameter Configuration

After power-on, the module conducts comprehensive hardware self-test, circuit inspection, E23 bus scanning and port signal verification to check the status of power supply, internal computing circuits, communication ports and rear loads, and enters standby mode with no abnormality detected. Operators select control modes and set PID parameters, ramp time, output amplitude, protection thresholds and multi-axis synchronous parameters accurately 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 subsequent high-speed closed-loop calculation.

Closed-loop Calculation & Drive Output

Based on preset control modes, the module executes adaptive PID regulation, ramp smoothing, accurate valve compensation and dynamic load correction relying on high-speed computing capability and optimized algorithms of Version 23 hardware. Output power and driving current are adjusted 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, ensuring steady process operation.

Bus Interaction & Multi-axis Coordinated Control

Real-time bidirectional data exchange is realized with upper systems through 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 and data linkage enable precise coordinated movement of multi-axis equipment, satisfying synchronous control demands of complex automatic production lines and precision molding 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, corresponding fault codes will be locked, power output cut off and alarms triggered to fully protect hydraulic valves, control modules and complete equipment, avoid fault escalation and reduce equipment damage risks.

Online Debugging & Maintenance Optimization

Online parameter tuning, real-time waveform observation, dynamic parameter optimization and automatic zero calibration help acquire optimal control parameters quickly for different production conditions. Large-capacity built-in fault log records long-term operating and fault data, facilitating rapid 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 hydraulic grinders and hydraulic finishing equipment. Leveraging high-precision computing performance and optimized closed-loop algorithms of Version 23 hardware, it accurately adjusts feed speed, cutting pressure, oil flow and positioning stroke, greatly enhancing machining accuracy, repetitive positioning precision and finished product consistency to meet strict process standards of high-end precision mechanical processing.

4.2 High-end Injection & Die-casting Industry

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

4.3 Heavy-duty Forging Hydraulic Machinery

Mainly applied to heavy-duty hydraulic equipment including hydraulic forging presses, precision presses, high-speed punching machines, bending machines and hydraulic shaping machines. Featuring excellent heavy-load adaptability and impact resistance of Version 23 hardware, it adapts to heavy-load, high-frequency and high-pressure impact conditions, realizing constant pressure control, accurate stroke speed regulation and load adaptive adjustment to ensure safe, stable and evenly powered operation of heavy machinery.

4.4 Precision Industrial Testing & Inspection 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.

4.5 Automated Multi-axis Synchronous Hydraulic Production Lines

Supported by E23 high-speed bus and multi-axis synchronous control function, it is extensively applied to automatic hydraulic production lines, hydraulic manipulators, synchronous lifting platforms, intelligent hydraulic control systems and multi-station hydraulic automatic equipment. It realizes precise coordinated movement of multiple devices and axes, unifies production rhythm and significantly boosts operational efficiency, synchronization accuracy and overall stability of automatic lines.