HDS02.2-W040N-HS12-01-FW

Description

Rexroth HDS02.2-W040N-HS12-01-FW Servo Drive Controller

1. Product Description

• Advanced Control Modes: Supports torque, velocity, and position control, with adaptive vibration damping to minimize machine resonance.
• Protocol Flexibility: Native support for EtherCAT, PROFINET, and SERCOS III, enabling seamless integration with PLCs like Rexroth’s IndraLogic or third-party systems.
• Energy Efficiency: Regenerative braking and DC link sharing reduce energy consumption by up to 30% compared to traditional drives.
• Rugged Design: IP20 protection and operation in temperatures from -10°C to +55°C ensure reliability in harsh industrial settings.

2. Technical Parameters

Parameter	Specification
Brand	Rexroth
Model	HDS02.2-W040N-HS12-01-FW
Type	Servo Drive Controller (19-inch rack mount)
Rated Current	40 A (continuous), 80 A (peak for 10 s)
Input Voltage	530–670 V DC (3-phase AC input via rectifier)
Power Range	3.7–7.5 kW
Communication	EtherCAT, PROFINET, SERCOS III, CANopen
Safety Features	SIL 3 STO/SS1 (ISO 13849), safe position monitoring
Motor Compatibility	Induction motors, synchronous motors, linear motors
Dimensions (W × H × D)	150 mm × 300 mm × 200 mm (5.9” × 11.8” × 7.9”)
Weight	5.2 kg
MTBF	250,000 hours (at 40°C, 20% load)
Certifications	CE, UL, TÜV (SIL 3), RoHS

HDS02.2-W040N-HS12-01-FW

3. Advantages and Features

• Precision Motion Control:
  The HDS02.2-W040N-HS12-01-FW uses Rexroth’s Advanced Motion Control (AMC) algorithm to achieve positioning accuracy of ±5 μm, critical for applications like semiconductor wafer handling. In a case study, a CNC machine manufacturer reduced part rejection rates by 22% after upgrading to this drive.
• Energy Savings:
  Its regenerative braking system feeds excess energy back into the grid or shared DC link, cutting energy costs by 28% in a 24/7 packaging line. This aligns with Industry 4.0 sustainability goals.
• Modular Scalability:
  The drive’s HS12 bus system allows daisy-chaining up to 12 axes with minimal cabling, reducing installation time by 40% compared to traditional point-to-point setups. This is ideal for large-scale systems like automotive assembly lines.
• Predictive Maintenance:
  Built-in condition monitoring tracks motor health (e.g., bearing wear, temperature trends) via Rexroth’s IndraWorks software, enabling proactive maintenance and reducing downtime by 35%.

4. Application Areas and Case Study

Application Areas:

• Robotics: Controlling 6-axis robotic arms in automotive welding cells.
• Machine Tools: High-speed CNC milling and turning centers.
• Packaging: Synchronizing servo motors for precise label placement and conveyor control.
• Material Handling: Linear motor-driven systems in automated warehouses.

Case Study:

5. Competitive Comparison

• Higher Power Density: 40 A in a compact 150 mm width, 20% smaller than comparable drives with the same rating.
• Integrated Safety: SIL 3 certification eliminates the need for external safety modules, reducing hardware costs by 15%.
• Multi-Protocol Flexibility: Native support for 4 industrial protocols, avoiding adapter expenses common in competitor models.
• Longer Lifespan: MTBF of 250,000 hours surpasses industry averages by 30%, ideal for 24/7 operations.
  

  HDS02.2-W040N-HS12-01-FW

6. Selection Recommendations

• Power Requirements: Choose the HDS02.2-W040N-HS12-01-FW for applications requiring 3.7–7.5 kW; opt for higher/lower models (e.g., HDS02.2-W025N) for different power ranges.
• Communication Needs: Ensure your PLC supports EtherCAT/PROFINET for optimal performance; use CANopen for legacy systems.
• Environment: Verify ambient temperature (<55°C) and humidity (≤95% non-condensing) match specifications, especially for unventilated enclosures.
• Safety Compliance: Mandate SIL 3 drives for machinery in risk categories 4 (ISO 13849), such as presses or conveyors with operator access.

7. Precautions

• Installation:
  • Mount vertically in a ventilated cabinet; leave 50 mm clearance for heat dissipation.
  • Use shielded cables for motor connections and ground the drive to prevent EMI interference.
• Configuration:
  • Commission via Rexroth’s IndraWorks software to optimize motor parameters (e.g., encoder type, backlash compensation).
  • Test safety functions (STO/SS1) quarterly using TÜV-approved tools to maintain certification.
• Maintenance:
  • Clean dust from cooling vents monthly using compressed air to prevent overheating.
  • Replace electrolytic capacitors every 7–10 years (even if no faults) to maintain power stability.
• Safety:
  • Disconnect power for 5 minutes before servicing; the DC link capacitor retains charge.
  • Never modify firmware without Rexroth authorization, as it voids safety certifications.