Description

REXRTOH VT-HNC100-1-23/W-08-P-0 R00958999

1. Basic Information

REXROTH VT-HNC100-1-23/W-08-P-0 is a single-axis digital hydraulic numerical control module and an industrial dedicated hydraulic motion closed-loop control unit. Designed for high-precision hydraulic servo control systems, it is compatible with various hydraulic servo actuators, proportional valves and servo valves. It achieves full closed-loop precise regulation of single-axis position, pressure and speed, serving as the core intelligent control component for hydraulic molding equipment, forging machinery, precision testing devices and automatic hydraulic production lines.

Adopting full-digital high-speed computing architecture, the module integrates axis control calculation, adaptive PID closed-loop regulation, signal acquisition and conditioning, logic control, bus communication and complete fault protection functions. Featuring exclusive single-axis independent control solution, it is equipped with Series 23 standard hardware, 8 integrated digital I/O ports and PROFIBUS DP high-speed bus structure. It directly drives hydraulic valve groups and servo actuators, thoroughly eliminating drawbacks of traditional hydraulic control including slow response, low precision, parameter drift and poor anti-interference performance. With high dynamic response, high-resolution regulation and load self-adaptability, it operates stably under severe working conditions such as high-frequency reciprocation, constant pressure and precision positioning, effectively improving machining accuracy, operational consistency and production stability of equipment.

Built with industrial wall-mounted reinforced modular design, it boasts compact and sturdy structure and excellent vibration and interference resistance. The standardized interface layout facilitates rapid on-site integration and 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, zero calibration and intelligent self-diagnosis. Suitable for 24-hour non-stop continuous operation, it runs steadily in complex hydraulic sites with heavy dust, intense vibration and strong electromagnetic interference, acting as the core control unit of high-precision single-axis hydraulic automatic control systems.

2. Technical Specifications

2.1 Core Electrical & Control Specifications

Power Supply: Standard 24VDC industrial control power supply with stable operating voltage ranging from 18VDC to 30VDC, adapting to on-site voltage fluctuation. Residual ripple is less than 1.5Vpp with superior power supply stability. It features balanced power consumption, rated output power of 100W and rated operating current of 2.3A. The built-in power-on soft-start circuit suppresses inrush current to fully protect rear valves, sensors and internal circuits and enhance system electrical safety.
Control Architecture: Pure digital single-axis independent control structure specially designed for precise single hydraulic axis regulation. It focuses on closed-loop calculation of position, pressure and speed of single equipment with dedicated control logic, fast response and high computing accuracy without multi-axis coupling interference, suitable for various single-station precision hydraulic processes.
Control Performance: Adopts dedicated Rexroth hydraulic control algorithm supporting flexible switching of position, pressure and speed closed-loop modes. Embedded high-precision adaptive PID regulation, feedforward compensation, friction compensation and valve lap compensation algorithms together with SSI Gray code acquisition deliver data resolution up to 0.001° per pulse, ultra-low steady-state error and outstanding dynamic follow-up capability. It realizes micron-level precision positioning as well as high-precision constant pressure and constant speed control.
Signal & Bus Configuration: Equipped with 8 standard digital input and output ports to meet regular logic signal interaction demands. It supports PROFIBUS DP high-speed industrial bus and is compatible with RS232 and RS485 serial communication, enabling high-speed data exchange, real-time parameter access, remote configuration and operating data upload for mainstream automatic bus control systems. The maximum adjustable data width reaches 28Bit to fit high-precision sensor signal collection.
Output Drive Capacity: Built-in stable power drive output directly drives common hydraulic proportional valves, servo valves and small-to-medium hydraulic actuators without external amplifiers, simplifying system hardware structure. The output signal features high linearity, no lag and no jitter with excellent operational stability.
Parameter Adjustability: Proportional, integral and differential gains are steplessly adjustable within 0-100%. Output amplitude, ramp time, limit threshold and alarm parameters are freely configurable. Local fine tuning and remote parameter setting via upper software are available for quick adaptation to diverse valve characteristics and field working conditions.
Protection Mechanism: Comprehensive multi-intelligent protection covers overcurrent, overvoltage, undervoltage, short circuit, overtemperature, abnormal load monitoring, signal breakage and bus fault protection. Fault codes are locked and abnormal output cut off instantly to prevent damage to valves, modules and complete equipment, avoid fault spread and greatly improve system reliability.
Environmental Adaptability: Wide temperature design with operating temperature from -10℃ to +55℃ and storage temperature from -20℃ to +70℃. Operating humidity ranges 5%~95% non-condensing. It has excellent dustproof, moistureproof, oil-resistant, anti-aging and anti-interference properties with IP20 protection grade, capable of long-term stable operation in harsh hydraulic industrial sites.

2.2 Physical & Structural Specifications

Installation Mode: Standard industrial wall-mounted structure fits installation on equipment bodies and control cabinets. Firm mounting with superior vibration resistance avoids loosening and displacement during long-term operation, applicable to equipment renovation and new unit assembly.
Structural Design: Compact integrated modular structure highly integrates computing unit, signal conditioning circuit, power drive circuit, bus interface, I/O ports and multi-protection circuits. Small size and neat layout occupy limited space and suit compact electric control schemes of various hydraulic equipment.
Weight: Lightweight industrial design with net weight about 0.5kg. The sturdy and lightweight structure balances operational stability and convenience of on-site assembly, replacement and debugging.
Material & Protection: The shell is made of high-strength flame-retardant industrial material processed with moisture-proof, anti-corrosion and anti-aging treatment, featuring oil resistance, impact resistance and corrosion resistance. Multi-layer shielding internal wiring effectively isolates external electromagnetic interference and maintains stable control signals without long-term parameter drift.
Interface Features: Clearly divided ports include 24VDC power port, RS232/RS485 serial port, PROFIBUS DP bus port, 8-channel digital I/O port and valve drive output port. Standard terminals allow convenient plugging and reliable contact with anti-loose structure, eliminating poor connection, wire breakage and signal anomalies caused by vibration.
Status Indication: Built-in LED indicators intuitively display power, operation, bus connection, I/O status and fault alarm information, facilitating rapid inspection, status recognition and accurate fault location to improve maintenance efficiency.

2.3 Core Functions & Compatibility Specifications

Core Functions: Integrated full-process functions include single-axis hydraulic valve drive, multi-mode precise closed-loop control, high-precision signal acquisition and conditioning, smooth ramp signal generation, accurate valve compensation, dynamic load adaptation, high-speed bus data interaction, 8-channel I/O logic control and intelligent fault diagnosis. It precisely regulates hydraulic pressure, speed and position, and supports parameter auto-tuning, automatic zero calibration and process parameter memory to satisfy diverse single-axis 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, I/O interaction 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 single-axis hydraulic servo valves, proportional valves, servo cylinders and hydraulic actuators. It connects seamlessly with PLCs, industrial controllers and upper monitoring systems of all brands. Supporting PROFIBUS DP protocol and compatible with RS232 and RS485 serial communication, 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, PROFIBUS DP bus scanning and verification of I/O and signal ports. It fully checks power supply, internal circuits, communication ports and rear loads and enters standby state when no abnormality is detected. Operators set control modes, PID values, ramp time, output amplitude, protection thresholds and I/O logic parameters via local ports, upper software or PLC bus to match on-site valve characteristics and actual working conditions.

Command Reception & Signal Processing

The module receives real-time single-axis position, pressure and speed setting commands from upper systems, and collects actual operating feedback signals from on-site SSI sensors and conventional feedback 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 for closed-loop calculation.

Closed-loop Calculation & Drive Output

Based on preset control modes, the high-speed computing unit executes adaptive PID regulation, ramp smoothing, valve compensation and dynamic load correction. Output power and driving current are adjusted precisely 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 and position.

Bus & I/O Interactive Control

Two-way real-time data exchange is carried out with upper control systems via PROFIBUS DP bus. Module operating status, output parameters, hydraulic data and fault information are uploaded continuously while control commands are received instantly. The 8 integrated digital I/O ports realize logic signal interaction of start-stop, limit, interlock and alarm to achieve integrated coordinated equipment control.

Real-time Monitoring & Intelligent Fault Protection

Power voltage, output current, module temperature, bus connection, I/O status, load condition and signal transmission are monitored throughout operation. Once faults such as overcurrent, overvoltage, overtemperature, short circuit, signal breakage, abnormal load, bus failure and I/O anomaly are detected, fault codes will be locked automatically, power output cut off and alarms triggered to protect 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 Precision Single-axis Hydraulic Machine Tools

Widely applied to single-axis CNC hydraulic machine tools, precision hydraulic grinders and hydraulic finishing equipment. Relying on high-precision single-axis closed-loop control, it accurately adjusts feed speed, cutting pressure and positioning stroke, greatly improving machining accuracy and product consistency to meet stringent precision mechanical processing requirements.

4.2 Small & Medium-sized Injection & Die-casting Equipment

Suitable for single-station hydraulic molding equipment including small and medium injection molding machines, die-casting machines and rubber molding machines. It precisely controls single-axis pressure and speed during mold clamping, injection, pressure holding and mold opening, stabilizes process parameters and reduces defects such as shrinkage, burr and deformation so as to raise product yield and production stability.

4.3 Small & Medium-sized Hydraulic Forging Equipment

Applied to heavy-duty hydraulic equipment such as single-axis hydraulic presses, small forging machines, precision punching machines and bending machines. It adapts to small and medium heavy-load and high-frequency conditions, realizing constant pressure control and accurate stroke speed regulation, and ensuring safe, stable and evenly powered equipment operation for conventional forging production.

4.4 Single-station Precision Testing & Inspection Equipment

Applicable to various single-station 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, speed and position, satisfying requirements of accurate data, stable operation, traceable parameters and high repeatability for testing equipment.

4.5 General Industrial Single-axis Hydraulic Automation Equipment

Suitable for single-axis hydraulic automatic equipment, hydraulic lifting platforms, single-station hydraulic manipulators and simple intelligent hydraulic control systems. Leveraging PROFIBUS bus communication and I/O logic control, it realizes automatic and intelligent equipment operation, simplifies control structure, reduces maintenance costs and improves operational stability and production efficiency.