Description
I. Product Overview
Rexroth VT-VPCD-1-1X/V0/1-0-1 (Part No. R901044346) is an original digital closed-loop control card specially designed for Rexroth A4VS (HS4 control) and A2V (EO4 control) axial piston pumps. Adopting full digital operation architecture, it replaces traditional analog control boards and realizes high-precision closed-loop regulation of hydraulic pump pressure, displacement, swing angle and power. With a 2ms ultra-fast scanning cycle, programmable multi-order filtering and automatic zero calibration functions, it completely solves parameter drift and low precision defects of analog control systems.
Equipped with standard RS232 local debugging interface and multi-channel programmable logic output, it supports on-site parameter configuration, real-time data monitoring and fault diagnosis. Featuring industrial wide-temperature resistance, strong anti-electromagnetic interference and maintenance-free stable operation, it has passed CE and UL certifications. Widely used in metallurgy, machinery, construction and petrochemical hydraulic systems, it serves as the core original spare part for aging board replacement and digital upgrading of traditional hydraulic control systems.
II. Hardware Structure and Composition
1. High-speed Digital Closed-loop Operation Unit
Built-in dedicated hydraulic control microprocessor and full-digital PID algorithm achieve 2ms high-speed scanning and real-time closed-loop adjustment. It dynamically corrects pump output deviation according to pressure, swing angle and power feedback signals, and supports adaptive parameter switching for no-load, light-load and heavy-load working conditions, ensuring stable and synchronous response of hydraulic system output.
2. High-precision Signal Acquisition and Filtering Unit
Adopting 8-order programmable low-pass filter + second-order active low-pass filter structure with adjustable cutoff frequency (10Hz～100kHz), it effectively filters industrial electromagnetic interference and signal clutter. The built-in automatic zero calibration and gain correction module ensures long-term control accuracy without parameter drift.
3. Multi-channel Programmable Switch Output Unit
Multiple logic-configurable switch output channels support custom functions via BODAC software, including swing angle control activation, pressure control activation, power limit activation, slave mode activation and precision window judgment output. It realizes linkage feedback and interlock control with upper PLC and hydraulic system.
4. Local Debugging Communication Unit
Standard RS232 serial interface supports direct local computer connection for parameter reading, modification, curve monitoring, fault diagnosis and program configuration. No complex network deployment is required, enabling efficient on-site debugging, calibration and troubleshooting.
5. Isolated Power Supply and Multi-level Protection Unit
24VDC wide-range isolated power supply with multi-level protections against overvoltage, undervoltage, overcurrent, reverse connection and surge. The fully coated PCB and industrial wide-temperature components ensure stable operation in harsh cabinet environments with high temperature, dust and strong electromagnetic interference.
6. Standard Plug-in Mounting Structure Unit
Standard industrial plug-in card design (100mm×160mm) matches Rexroth original hydraulic electric rack with unified interface and mounting dimensions. It supports direct in-situ replacement without cabinet and wiring modification, minimizing equipment maintenance downtime.
III. Technical Specifications
(1) Electrical Parameters
1. Power Supply: 24VDC industrial DC power, rated operating current 3.5A
2. Control Mode: Full digital closed-loop PID adaptive regulation, scanning cycle 2ms
3. Filter Specification: 8-order programmable low-pass + 2-order active low-pass, 10Hz～100kHz adjustable cutoff frequency
4. Communication Interface: RS232 serial debugging interface for local configuration and monitoring
5. Output Function: Multi-channel programmable logic switch output, customizable hydraulic control logic
6. Applicable Pump Model: A4VS (HS4), A2V (EO4) series axial variable piston pump
7. Control Performance: High precision closed-loop regulation, no temperature drift or zero offset
(2) Environmental Parameters
Operating Temperature: 0℃～+50℃; Storage Temperature: -20℃～+70℃
Relative Humidity: 5%～95%RH, non-condensing, free of corrosive gas and conductive dust
EMC Compliance: Industrial IEC electromagnetic compatibility standard, strong anti-interference capability
Certifications: CE, UL industrial electrical safety certification
Ingress Protection: IP20, for indoor enclosed hydraulic electric cabinet installation
(3) Mechanical Parameters
Mounting Mode: Standard industrial rack plug-in embedded installation
Dimension: 100mm × 160mm
Net Weight: Approx. 0.2kg
Protection Process: PCB full three-proof coating, vibration and aging resistance
Origin: Germany
IV. Product Functions and Features
1. Precise Digital Closed-loop Control Eliminates Working Condition Drift
The full-digital operation algorithm completely avoids temperature drift and parameter aging defects of analog circuits. It realizes triple closed-loop regulation of hydraulic pump pressure, swing angle and power, dynamically adjusts pump displacement according to load changes, suppresses system pressure and flow fluctuation, and improves hydraulic equipment operation stability and processing accuracy.
2. Programmable Adaptive Regulation Adapts to Complex Loads
Customizable PID parameters, filter thresholds and output logics support matching multiple working conditions such as constant pressure, constant flow and constant power. The load adaptive recognition function automatically switches adjustment modes, solving hydraulic system jitter, response lag and poor working condition adaptability problems.
3. High-order Filter and Auto-calibration Ensure Long-term Stability
Dual-layer multi-stage filtering purifies feedback signals and eliminates electromagnetic interference noise. Built-in zero self-calibration and gain correction functions maintain long-term high-precision control without manual repeated calibration, reducing operation and maintenance workload and avoiding hydraulic pump surge and jitter faults caused by signal abnormality.
4. Multi-logic Output Supports Automatic System Integration
Configurable switch output channels feed back pump working state, precision interval and fault information in real time, realizing linkage control, fault alarm and safety interlock with upper PLC. It improves the automation integration level of intelligent hydraulic production lines.
5. Modular Standard Design Reduces Maintenance Downtime
Unified mounting and interface specifications support plug-and-play in-situ replacement of old boards. The dedicated debugging software supports one-click parameter backup and import, enabling rapid commissioning and operation after replacement, minimizing production shutdown losses.
6. Industrial High-reliability Design Realizes Maintenance-free Operation
Fanless passive heat dissipation, wide-temperature components and three-proof coating adapt to harsh cabinet environments. No vulnerable moving parts, low failure rate and long MTBF meet the 24/7 continuous operation requirements of industrial production equipment.
V. Application Scenarios
1. Precision hydraulic control for metallurgical rolling mills, straightening machines and coiling machines.
2. Closed-loop regulation of constant pressure/flow/power for hydraulic units of injection molding machines, die-casting machines and precision machine tools.
3. Working condition adaptive control for main hydraulic pumps of shield machines, tunnel boring machines and mining engineering machinery.
4. Digital upgrading and replacement of aging analog hydraulic control boards with accuracy drift and frequent faults.
5. Precision optimization and logic upgrading of automatic hydraulic production line control systems.
