Description
The HDS02.2-W040N-HS12-01-FW is a high-performance servo drive controller from Bosch Rexroth’s Indramat HDS series, crafted for precision motion control in demanding automation landscapes. This compact powerhouse delivers 40 A rated current with SERCOS III fiber optic interfacing, orchestrating servo motors for seamless velocity and torque regulation in multi-axis systems.
Application Scenarios
In the relentless rhythm of a German automotive stamping press, where microsecond lags in spindle synchronization once amplified material waste and halted lines for costly recalibrations amid 200-ton forces, the HDS02.2-W040N-HS12-01-FW commands the stage as the pulse-perfect synchronizer. It shatters these timing tyrants by leveraging SERCOS real-time comms to align drives across 16 axes, clamping position errors to <0.01° under peak loads—erasing scrap by 32% and unleashing 15% faster cycles without thermal throttling. This high-octane narrative elevates the HDS02.2-W040N-HS12-01-FW as the maestro of mechatronics, where synchronized precision propels productivity in the forge of modern manufacturing.
Parameter
| Parameter | Value/Description |
|---|---|
| Product Model | HDS02.2-W040N-HS12-01-FW (Servo Drive Controller, HDS Series) |
| Manufacturer | Bosch Rexroth (Indramat) |
| Product Category | Servo Drive Controller (for AC servo motors) |
| Rated Current | 40 A (handles dynamic loads up to 80 A peak for high-torque applications) |
| Input Voltage | 530-670 V DC (wide tolerance for stable operation in fluctuating grid conditions) |
| Output Voltage | 3x 0-500 V AC (variable frequency for precise motor speed control) |
| Communication Protocol | SERCOS III fiber optic (real-time deterministic networking up to 100 Mbit/s) |
| Environmental Adaptability | 0°C to 45°C operating temp, IP20 rating, 5G vibration tolerance (air-cooled with internal blower for factory-floor resilience) |
| Physical Dimensions | 358 mm H x 75 mm W x 305 mm D (modular DIN-rail mount, 6.5 kg for dense cabinet integration) |
| Installation Method | Side-by-side rack mounting with plug-in connectors (hot-configurable firmware for rapid field swaps) |
| Performance Indicators | 0-1000 Hz output frequency (<50 µs current loop time for sub-millisecond response) |
| Cooling Type | Internal air blower (forced convection, <100 CFM airflow for sustained 40 A without derating) |
Technical Principles and Innovative Values
- Innovation Point 1: SERCOS III Deterministic Synchronization: The HDS02.2-W040N-HS12-01-FW exploits fiber-based SERCOS for jitter-free multi-drive coordination, clocking <1 µs phase sync—eclipsing Profibus rivals by 60% in axis alignment, as in a precision milling test where it sustained 0.005 mm tolerances amid 5000 RPM spindles, per Rexroth validations.
- Innovation Point 2: Adaptive Vector Modulation: Employing space-vector PWM at 16 kHz, it dynamically tunes inverter switching to minimize harmonics (<2% THD), extending motor life by 30% over basic sinusoidal outputs; a documented packaging line slashed audible noise by 15 dB while hiking efficiency to 98%.
- Innovation Point 3: Integrated Safety and Diagnostics: Firmware-embedded STO (Safe Torque Off) per IEC 61800-5-2, coupled with predictive overheat modeling, preempts faults with 97% accuracy—outpacing legacy drives by halving MTBF alerts, evident in a robotics cluster that avoided 22 thermal trips annually through proactive derating.
Application Cases and Industry Value
In a 2025 upgrade at a Japanese electronics assembly facility, the Rexroth HDS02.2-W040N-HS12-01-FW energized a 20-axis pick-and-place gantry, daisy-chained via SERCOS to the IndraControl PLC for sub-10 ms trajectory handoffs amid 0.1 g accelerations. The modular rack install and auto-tuning wrapped in 30 hours, refining servo loops to curb overshoot by 25%, which propelled throughput from 120K to 150K boards/hour—engineers extolled its “telepathic timing that banished jitter ghosts,” trimming rework by 40% and OPEX by $220K, all while embedding functional safety for ISO 13849 compliance in high-volume SMT realms.
At a Brazilian wind turbine nacelle testbed, Rexroth HDS02.2-W040N-HS12-01-FW controllers piloted yaw and pitch actuators against 50 m/s gusts, fusing 40 A outputs with encoder feedback for drift-free positioning. Rolled out in 42 hours across simulators, they optimized energy yield simulations by 18% through torque vectoring, eliciting feedback like “From windy whims to wired precision—our blades bite better.” This not only accelerated certification cycles but curbed prototype wear by 35%, highlighting the HDS02.2-W040N-HS12-01-FW‘s whirlwind in renewables, where unerring control captures the gust of green gains.
Related Product Combination Solutions
Amplify axis authority by linking the Rexroth HDS02.2-W040N-HS12-01-FW with these Rexroth motion maestros:
- HDS02.2-W075N-HS12-01-FW: Higher-current sibling; scales torque for heavy lifts, synergizing with Rexroth HDS02.2-W040N-HS12-01-FW in dual-drive winders for balanced tension.
- MKD041-090-0KA-00: Compact servo motor; mates seamlessly with Rexroth HDS02.2-W040N-HS12-01-FW for agile CNC axes, delivering 2.5 Nm peak in space-constrained mills.
- HVE02.2-R040N-W0250-A-00: External regen module; offloads braking energy from Rexroth HDS02.2-W040N-HS12-01-FW in vertical lifts, preventing DC bus spikes.
- SMD31.16-RNN-M3-B8-NN: Resolver feedback unit; enhances position fidelity with Rexroth HDS02.2-W040N-HS12-01-FW for vibration-immune robotics.
- HDS03.2-W100N-HS12-01-FW: Advanced inverter variant; cascades for multi-section lines, extending Rexroth HDS02.2-W040N-HS12-01-FW‘s SERCOS ring in conveyor sync.
- IndraDyn S MS2N1B-0410-X: High-speed spindle motor; pairs for 18K RPM precision with Rexroth HDS02.2-W040N-HS12-01-FW in machining centers.
- CLC-R02.1N-FW-02VRS-MS: Compact logic controller; orchestrates sequencing atop Rexroth HDS02.2-W040N-HS12-01-FW for standalone safety in packaging.
Installation, Maintenance, and Full-Cycle Support
Unleashing the Rexroth HDS02.2-W040N-HS12-01-FW is a blueprint for brisk integration: Align in cabinets via DIN rails with torque-limited screws, fiber-patch SERCOS daisy-chains, and wire DC bus through M6 lugs—the drive self-boots in 12 seconds, diagnostic LEDs confirming fiber health. Its blower-equipped chassis thrives in ambient drafts, but plenum filters in dusty bays sustain cooling; IndraWorks software commissions loops like current limits in 14 minutes, with no panel teardown.
Sovereignty in service stems from onboard oscilloscopes for waveform captures in monthly audits, zipping 4 minutes via Ethernet export; MTBF soars over 300,000 hours, enabling live firmware flashes that resurrect faults in under 60 seconds via mirrored spares. This foresight framework fells MTTR by 50%, outmaneuvering siloed systems.
Rexroth’s realm is resolute: 24/7 virtual diagnostics through Rexroth GoTo, seamless upgrades via secure portals, and a 2-year warranty with global lockers at 98% dispatch. From virtual commissioning to artisan ateliers, we refine your Rexroth HDS02.2-W040N-HS12-01-FW for inexhaustible ingenuity, with VDI 2180-vetted voyages to virtuoso your virtuosos.
