Description

REXRTOH SYHNC100-NIB-22a/W-24-P-D-E24

1. Basic Information

REXROTH SYHNC100-NIB-22a/W-24-P-D-E24 is a high-performance digital axis control drive module of SYHNC100 series, serving as an industrial dedicated closed-loop control unit for hydraulic and servo systems. Designed for high-precision hydraulic servo systems, proportional valve control systems and multi-axis synchronous motion applications, it acts as a core drive component to realize accurate closed-loop regulation of equipment speed, pressure and position. It is widely applicable to high-end industrial equipment including machine tools, die-casting machines, injection molding machines, forging presses and automated production lines.

Adopting full digital signal processing architecture, the module integrates servo drive, PID closed-loop calculation, signal acquisition, logic control and fault diagnosis functions. It can directly drive proportional valves, hydraulic servo cylinders and servo motors, effectively eliminating temperature drift, interference and zero offset defects existing in traditional analog control. Equipped with 22kW driving capacity, 24VDC industrial power supply and advanced E24 configuration, it delivers fast dynamic response, high-precision repetitive positioning and steady pressure maintenance, greatly improving processing consistency and operational stability of equipment.

Built with industrial reinforced modular structure, it features compact layout and strong vibration and interference resistance. It supports mainstream industrial bus communication such as EtherCAT and Modbus, enabling seamless connection with PLC, upper computer systems and full-range Rexroth automation devices. Featuring plug-and-play configuration, remote parameter debugging and intelligent fault diagnosis, it adapts to long-term continuous operation and harsh industrial working conditions, and serves as the core control and drive unit for high-end hydraulic automation equipment.

2. Technical Specifications

2.1 Core Electrical & Control Specifications

Power Supply: Standard 24VDC industrial control voltage, operating voltage range 18–30VDC, suitable for industrial environments with wide voltage fluctuation. Stable power consumption and power-on soft-start function restrain inrush current and protect rear valves and circuit components.
Drive Rating: 22kW power drive configuration, matching medium and large hydraulic servo actuators, large-flow proportional valves and heavy-load hydraulic cylinders. It provides sufficient driving torque and strong load adaptability to meet heavy-load, high-speed and high-frequency reciprocating operation requirements.
Control Performance: Full digital closed-loop control algorithm supports switchable position, pressure and speed closed-loop modes. Built-in high-precision PID, feedforward compensation and friction compensation algorithms ensure fast response and negligible steady-state error, achieving micron-level positioning accuracy and stable pressure control.
Signal & Bus Configuration: Supports collection and output of standard industrial analog signals compatible with 4-20mA and 0-10V signals. Integrated high-speed industrial bus ports comply with EtherCAT and Modbus protocols to realize high-speed data exchange, real-time parameter access and multi-axis synchronous control.
Output Capacity: Maximum driving output current reaches 1.5A, capable of directly driving most industrial servo proportional valves without external amplifier boards for simplified system structure. The output signal boasts high linearity and favorable dynamic follow-up performance without lag and jitter.
Protection Mechanism: Multiple protection functions including overcurrent, overvoltage, undervoltage, short circuit, overtemperature and abnormal load monitoring are embedded. Abnormal output can be cut off timely to prevent burnout of valves, modules and complete equipment, enhancing overall system safety.
Environmental Adaptability: Wide operating temperature range from -20℃ to +60℃, storage temperature -40℃ to +85℃. Operating humidity: 5%~95% non-condensing. It offers excellent dustproof, moistureproof, oil-proof and anti-electromagnetic interference performance, capable of stable long-term operation in dusty, vibrating and strong electromagnetic industrial sites.

2.2 Physical & Structural Specifications

Installation Mode: Standard industrial DIN rail mounting fits standard layout of electrical control cabinets and dense cabinet installation. It is easy to mount and firmly fixed against equipment vibration without loosening.
Structural Design: Compact integrated modular structure highly integrates drive circuits, arithmetic units, bus interfaces and protection circuits. Small footprint saves cabinet space and adapts to compact electric control schemes of various automation equipment.
Material & Protection: The shell is made of high-strength flame-retardant industrial material with outstanding anti-aging, anti-corrosion and impact resistance for long-term industrial service. Multi-layer shielding design isolates external electromagnetic interference and guarantees pure and stable control signals.
Interface Features: Clearly partitioned ports cover power, analog signal, bus communication and valve drive output terminals. Standard terminals allow convenient plugging and reliable contact with anti-loose structure, avoiding wire breakage and signal abnormality caused by vibration.
Status Indication: Built-in LED indicators visually display power, operation, bus connection and fault alarm status, facilitating on-site routine inspection and rapid fault location.

2.3 Core Functions & Compatibility Specifications

Core Functions: Integrated multi-mode closed-loop control realizes precise regulation of position, pressure and speed. Advanced functions such as multi-axis synchronous control, dynamic load adaptation, parameter self-tuning, zero calibration and friction compensation are available. Real-time operating status monitoring, automatic fault code recording, intelligent diagnosis and protective shutdown are supported.
Integration Features: The all-in-one module accomplishes full procedures including signal acquisition, operational control, valve drive, bus communication and fault protection. No additional amplifiers or conversion modules are required, simplifying wiring, reducing fault points and cutting equipment costs.
Compatibility: Fully compatible with all Rexroth hydraulic servo valves, proportional valves and hydraulic cylinders. It can connect with PLCs, industrial controllers and upper configuration systems of various brands. Supporting standard industrial bus protocols, it fits mainstream automatic control system architectures and can be applied to new equipment commissioning and old equipment renovation projects.
Reliability & Practicability: Industrial durable design enables 24-hour non-stop continuous operation with minor long-term drift and high stability. Remote software debugging, parameter backup and restoration support maintenance without disassembly, shortening downtime and improving overall operational efficiency.

3. Working Principle

System Initialization & Parameter Configuration

The module conducts automatic self-test, hardware initialization, bus scanning and port detection after power-on, and enters standby state with confirmed normal power supply, circuits, bus and loads. Engineers set closed-loop modes, PID values, limit thresholds, output amplitude and synchronous parameters via supporting upper software or PLC bus to match actual working conditions and actuator characteristics.

Signal Acquisition & Deviation Calculation

The module collects command signals from upper systems and real-time position, pressure and speed feedback signals from on-site sensors simultaneously. Internal filtering eliminates interference noise, and deviations between set values and actual values are calculated accurately to provide valid data sources for closed-loop operation.

Closed-loop Calculation & Drive Output

Based on preset control modes, high-speed DSP executes PID regulation, feedforward compensation and dynamic correction. Output current and voltage are adjusted in real time to drive servo proportional valves accurately, correcting operational deviations and enabling actuators to follow preset tracks rapidly and steadily for high-precision dynamic control.

Bus Interaction & Multi-axis Synchronization

High-speed data interaction is realized with upper systems via EtherCAT and Modbus buses. Real-time operating parameters, module status and fault information are uploaded while control commands are received. Multi-module clock synchronization ensures coordinated movement of multiple axes to satisfy complex linkage process requirements.

Status Monitoring & Fault Protection

Power voltage, output current, module temperature, bus condition and load status are monitored throughout operation. Once faults such as overcurrent, overvoltage, overtemperature, short circuit, wire breakage and servo abnormality are detected, fault codes will be locked, drive output cut off and alarm signals uploaded immediately to protect equipment and maintain system stability.

Debugging & Maintenance

Online parameter modification, real-time waveform observation, dynamic curve monitoring, zero calibration and parameter self-tuning optimize control performance efficiently. Fault log storage and query assist maintenance staff in troubleshooting and performance optimization conveniently.

4. Application Scenarios

4.1 High-end Hydraulic Machine Tools

Widely used in high-precision hydraulic and numerical control machine tools to achieve accurate closed-loop control of feed shaft position and pressure. It improves machining precision, repetitive positioning accuracy and processing consistency, suitable for high-precision cutting and forming processes.

4.2 Die-casting & Injection Molding Industry

Applied to die-casting machines, injection molding machines and rubber molding equipment. It precisely controls pressure and speed during mold clamping, injection, pressure holding and mold opening procedures, stabilizing molding processes and reducing product defects such as shrinkage and burrs so as to raise yield rate and production stability.

4.3 Forging & Heavy Machinery

Deployed on hydraulic forging presses, punching machines and heavy-duty presses. Supported by 22kW high-power driving capacity, it adapts to heavy-load high-frequency working conditions, maintains constant pressure and precise stroke control, and guarantees safe, stable and efficient operation of heavy machinery.

4.4 Automated Multi-axis Synchronous Production Lines

With high-speed bus and multi-axis synchronization functions, it is applied to automated assembly lines, hydraulic manipulators and lifting synchronous platforms. Coordinated multi-axis movement unifies production rhythm and synchronous actions, enhancing operational efficiency and stability of automated lines.

4.5 General Industrial Precision Hydraulic Systems

Applicable to various industrial scenarios requiring high-precision hydraulic closed-loop control, including test equipment, inspection devices, precision pressure regulating systems and constant pressure control systems. It provides stable, efficient and accurate core drive and control support for all kinds of precision hydraulic automation equipment.