Description
1. Product Overview
Rexroth PPC‑R22.1N‑T‑NN‑P1‑NN‑FW is a high‑performance multi‑axis motion and logic integrated controller under Bosch Rexroth Indramat series, belonging to the VisualMotion 10 product family. It is a core control unit developed for high‑precision motion‑control applications in industrial automation. Adopting the industry‑standard RECO 02 modular architecture, the controller is equipped with optical‑fiber SERCOS bus, multi‑serial‑port communication and industrial bus interfaces. It realizes synchronous control of multi‑axis servo systems, equipment logic operation and data acquisition, and is perfectly matched with DIAX04 series digital drive systems.
Featuring industrial‑grade storage and highly‑stable hardware circuits, the unit supports wide‑range industrial power supply and delivers excellent environmental adaptability and anti‑interference performance. It meets high‑speed and high‑precision control requirements for automatic production lines, precision machine tools and special‑purpose equipment. Supported by visual configuration software, it enables convenient system configuration, program debugging and equipment maintenance, serving as a core modular control device for industrial motion‑control applications.
2. Functional Features
High‑precision Multi‑axis Motion Control
Supports synchronous linkage control of multi‑axis servos. Real‑time communication with servo drives is realized via high‑speed SERCOS optical‑fiber bus with selectable baud rates of 2 M, 4 M, 8 M and 16 M. The response latency can be as low as 400 μs. It accurately executes sophisticated motion algorithms including positioning, interpolation, synchronization and follow‑up, satisfying high‑precision operating conditions such as precision machining and high‑speed transmission.
Versatile Communication Expansion Capability
Integrates multiple industrial communication interfaces and complies with RS‑232, RS‑422 and RS‑485 serial standards. Serial‑port baud rate ranges from 9600 bps to 115200 bps. It is equipped with Industrial Ethernet, ARCNET and DeviceNet bus interfaces to support cross‑device data exchange and networked control. It can be easily integrated into industrial automation systems to realize equipment networking and centralized management.
Reliable Logic Control and Data Processing
Built‑in independent logic computing core performs synchronous operation of discrete‑signal logic, sequence control and motion control. Equipped with 4 MB flash memory and 64 KB non‑volatile nvRAM, it reliably stores control programs, parameter recipes and operating data. Core data is retained upon power‑off to ensure continuous stable equipment operation.
Convenient Debugging & Maintenance
Compatible with VisualMotion Toolkit visual configuration software for program editing, parameter setting, on‑line debugging and fault diagnosis. The onboard H1 digital display module shows model number, firmware version, operating hours and fault codes in real time. Built‑in self‑check alerts cover power‑fail protection, startup lock‑up and firmware anomalies to reduce maintenance workload.
Industrial‑Grade Anti‑interference Performance
Complies with EN 55022 Class A EMC standard to resist electromagnetic interference in factory environments. Operates under wide temperature and humidity conditions with relative humidity 10 %‑95 % RH (non‑condensing). The hardware circuits are industrially reinforced for harsh industrial operating conditions.
3. Technical Specifications
3.1 Electrical Specifications
Rated supply voltage: 24 VDC Operating voltage range: 19.2 VDC‑30 VDC (‑15 % / +20 % voltage tolerance, compliant with EN61131‑2:1994) Max. I/O bus power: 52 W Digital inputs: 3‑channel, minimum input current 10 A per channel Digital outputs: 2‑channel passive contact outputs, max. 0.5 A per channel, maximum output delay 400 μs
3.2 Storage & Operation Specifications
Flash memory: 4 MB Non‑volatile RAM: 64 KB nvRAM Program configuration: serial‑port online configuration, local firmware storage Menu auto‑reset time: 20 s
3.3 Communication Specifications
Serial interfaces: RS‑232 / RS‑422 / RS‑485 universal interface Serial‑port baud rate: 9600 bps (default) ~ 115200 bps (max.) Fiber‑optic bus: SERCON 410B SERCOS optical‑fiber interface, multi‑baud‑rate support Expansion buses: DeviceNet, ARCNET, Industrial Ethernet
3.4 Environmental & Protection Specifications
Protection class: IP20 (per EN 60529) Operating humidity: 10 %‑95 % RH (non‑condensing) EMC rating: EN 55022 Class A Mounting: RECO 02 standard rack‑mount
4. Hardware Configuration & Structural Advantages
4.1 Core Hardware Configuration
Adopts integrated modular hardware design with industrial‑grade motion‑control chip, independent logic computing unit and bus communication unit. Clear hierarchical hardware architecture with well‑defined functional partitions. Standard H1 digital diagnostic display for real‑time operating‑status visualization. Standard PC‑card firmware expansion slot compatible with full‑range matching firmware modules. Onboard high‑precision I/O circuits guarantee stable and timely signal acquisition & output. Axis quantity can be expanded via passive expansion modules to meet multi‑axis equipment upgrade requirements.
4.2 Structural Design Advantages
RECO 02 standard rack‑mount form factor, compact and highly interoperable. Directly fits Rexroth standard industrial racks and allows dense multi‑module installation to save cabinet space. Housing made of industrial flame‑retardant material; internal circuits are reinforced against dust and vibration. IP20 rating offers protection against workshop dust and minor mechanical impact.
Plug‑in modular design enables quick installation and removal. Interfaces are logically grouped for easy wiring and servicing. Fan‑less silent architecture minimizes failure points and lowers long‑term maintenance cost for continuous industrial operation. Backplane‑bus‑based architecture supports seamless system integration with series‑compatible I/O and drive modules.
5. Working Principle
The Rexroth PPC‑R22.1N‑T‑NN‑P1‑NN‑FW controller implements an integrated mechanism of “logic operation + motion control + bus communication”. Its workflow consists of four phases: command reception, computation processing, execution output and status feedback.
First, programs, motion parameters and logic parameters are edited and configured in VisualMotion Toolkit and saved into flash memory and nvRAM. Upon power‑on, the core control unit initializes hardware interfaces, bus modules and I/O ports. After self‑check passes, the controller enters standby mode.
During runtime, the controller receives commands from host computer or local application. On one hand, the logic unit executes discrete‑signal, sequence and interlock logic operations. On the other hand, motion‑control algorithms perform complex multi‑axis interpolation, synchronization and positioning calculations to generate precise drive commands.
Control commands are transmitted over high‑speed SERCOS optical‑fiber bus to DIAX04 servo drives to actuate servo motors. Meanwhile, drive operational data and I/O status are collected through serial and industrial buses. The controller compares and corrects feedback signals in real‑time and dynamically adjusts control parameters to form closed‑loop control for high accuracy and stability.
In addition, supply voltage, firmware execution and hardware fault signals are continuously monitored. Fault codes are displayed and protection mechanisms are triggered on anomalies, with fault data logged to ensure safe equipment operation.
6. Application Scenarios
Precision Machine‑Tool Industry
Suitable for CNC milling machines, grinders, punching machines and engraving machines. Delivers precise workpiece positioning and high‑speed interpolation for metal precision machining and non‑metal engraving, improving machining accuracy and production efficiency.
Automatic Production Lines
Applied to electronic assembly lines, packaging lines, sorting conveyors and automatic assembly equipment. Realizes material handling, pick‑and‑place, automatic packaging and sorting via multi‑axis coordination and interlock logic for mass continuous production.
Plastics & Molding Equipment
Compatible with injection molding machines, extruders and blow‑molding machines. Precisely controls screw speed, mold movement and material extrusion. Multi‑process coordinated operation ensures consistent product quality for standardized large‑scale plastics manufacturing.
Logistics & Handling Equipment
Deployed for handling robots, gantry truss manipulators and automatic loading/unloading machines. Provides fast response and accurate positioning for material transfer, workstation loading‑unloading and stacking in smart workshops and warehousing logistics.
Special‑Purpose Industrial Automation Equipment
Widely used in automotive component machinery, new‑energy battery production equipment and 3C inspection equipment. Flexible configuration, rich communication options and stable control performance satisfy customized high‑precision requirements for non‑standard automation systems.
