REXRTOH VT-HNC100-2-30/P-I-00/G02 R901134616 Digital Hydraulic Axis Controller

Description

1. Product Overview

VT‑HNC100‑2‑30/P‑I‑00/G02 (Order No. R901134616) is a digital hydraulic axis controller of the Rexroth HNC100 series, a dedicated closed‑loop control unit for electro‑hydraulic servo systems. Developed for electro‑hydraulic servo drive systems, it is widely applied in high‑precision hydraulic positioning and force‑control scenarios such as metallurgical rolling mills, forging machine tools, injection‑molding equipment, material testing machines, construction machinery, and power‑station hydraulic actuators.

Receiving setpoint commands from the upper‑level PLC, the controller collects feedback signals from displacement and pressure sensors, outputs drive signals to control electro‑hydraulic servo valves, and realizes position closed‑loop, pressure closed‑loop and force closed‑loop control for hydraulic axes. Integrated with signal conditioning, PID control, status diagnosis and bus communication functions, it serves as the core control hardware of electro‑hydraulic servo systems.

It adopts standard DIN‑rail mounting. Having passed reliability tests including high‑low temperature, vibration‑shock and EMC electromagnetic compatibility, it supports 7×24‑hour continuous operation in industrial sites. It is frequently used for spare‑part replacement, equipment overhaul and technical‑retrofit projects of hydraulic servo systems.

2. Functional Features

2.1 Multi‑Mode Closed‑Loop Control

Supports position closed‑loop, pressure closed‑loop and force closed‑loop, as well as switch‑over control between position and pressure modes, suitable for processes including hydraulic‑servo‑axis positioning, pressure holding and force loading. Built‑in adaptive PID algorithm supports gain adjustment and feed‑forward compensation to improve dynamic response and suppress overshoot.

2.2 Multi‑Type Sensor Signal Acquisition

Accepts analog feedback signals from LVDTs, magnetostrictive displacement sensors, strain‑gauge pressure sensors and other devices. It filters, amplifies and conditions sensor signals to acquire high‑precision feedback values.

2.3 Servo‑Valve Drive Output

Provides standard ±10 V analog control signals to drive electro‑hydraulic servo / proportional valves. Output polarity, amplitude limiting and ramp rate are configurable to protect hydraulic valves and actuating cylinders.

2.4 Hardware Self‑Diagnosis and Fault Alarm

Continuously monitors supply‑voltage level, sensor wire breakage, signal over‑range, servo‑valve drive faults and internal hardware abnormalities. Faults trigger relay‑alarm output, and fault codes can be displayed on the upper‑level HMI.

2.5 Digital Communication and Analog Interfaces

Integrated analog input/output and digital DI/DO channels. It can receive setpoints from the host via bus and upload axis position, pressure and fault status. Parameters can be set locally via panel or configured by upper‑level software.

2.6 Standard DIN‑Rail Mounting

Industrial snap‑on mounting onto standard DIN rails for easy installation and removal. Compact modular design simplifies cabinet wiring and facilitates spare‑part replacement.

2.7 Harsh‑Industrial‑Environment Adaptability

Wide operating‑temperature range, vibration‑shock resistance and EMC protection. It adapts to high‑dust and heavy‑interference cabinet conditions in metallurgy and heavy‑duty machinery.

3. Technical Specifications

3.1 Core Compatibility Parameters

3.2 Electrical Performance Parameters

3.3 Environmental and Physical Parameters

4. Hardware Configuration & Structural Advantages

4.1 Core Hardware Configuration

VT‑HNC100‑2‑30/P‑I‑00/G02 consists of analog‑signal‑conditioning unit, A/D conversion module, main‑control‑processing MCU, D/A servo‑valve drive output unit, DI/DO digital‑logic circuit, on‑board 24 V power‑conversion unit, self‑diagnosis monitoring circuit, status LED indicators, terminal‑block assembly and DIN‑rail snap‑on housing.

Position / pressure setpoint commands issued by the upper‑level PLC are sampled via the controller’s A/D converter. Feedback signals from displacement and pressure sensors are fed into terminals, conditioned and sent to the main‑control unit. The controller compares setpoints against actual feedback values and outputs analog drive signals to the servo valve via PID calculation to regulate cylinder motion. The self‑diagnosis unit continuously monitors sensor loops, power supply and drive channels and activates relay alarms upon faults. All field wiring connects via front‑end terminals, and the modular housing protects the internal circuit board.

4.2 Structural & Engineering Advantages

Snap‑on DIN‑rail mounting simplifies spare‑part replacement without extensive modification of on‑site hydraulic piping, shortening maintenance downtime. Built‑in signal‑conditioning circuits suppress interference from long‑sensor cables and guarantee feedback‑signal accuracy. A single controller integrates multiple closed‑loop functions, reducing the number of cabinet‑mounted modules and saving cabinet space. Digital PID supports on‑site online parameter tuning for convenient commissioning. Built‑in fault‑diagnosis functions rapidly localize faults in sensors and valve‑control loops to reduce troubleshooting time. The Rexroth HNC series offers good compatibility and is widely used for retrofits and spare‑part‑replacement projects of legacy hydraulic equipment.

5. Working Principle

Working sequence of VT‑HNC100‑2‑30/P‑I‑00/G02: Upper‑level setpoint command → analog / bus setpoint input → A/D sampling; Sensor feedback signal → terminal access → signal conditioning → A/D sampling; Main‑control unit compares setpoint versus actual feedback → PID + feed‑forward calculation → D/A conversion outputs servo‑valve drive signal → electro‑hydraulic servo valve regulates hydraulic‑oil flow → cylinder executes motion; Self‑diagnosis circuit runs in parallel to monitor hardware and sensor loops.

During operation, the host system transmits target‑position or target‑pressure commands. The controller samples cylinder‑displacement and cavity‑pressure feedback in real time, computes deviations, and outputs corresponding control voltages to drive the servo valve. It adjusts oil flow into the cylinder so that the cylinder quickly tracks setpoints to realize position closed‑loop or pressure‑holding control.

The controller continuously monitors power‑supply status, sensor wire breaks, signal over‑range and output‑drive faults. When an anomaly is detected, the front‑panel fault LED illuminates and the relay sends alarm signals to PLC/HMI to notify maintenance personnel and prevent equipment damage caused by hydraulic‑axis runaway.

6. Common Faults and Troubleshooting

6.1 Power‑on, fault LED stays on; system reports controller fault

6.2 Communication / command anomaly; upper‑level setpoints cannot be received

6.3 Hydraulic‑axis oscillation, large positioning deviation, unstable cylinder motion

6.4 Persistent sensor‑wire‑break alarm while sensor hardware is intact